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ACH550 I, O & M 2011 (Download PDF)

1. User Power Iji 1 VI In Q Cable Guides 2 Ground i i 6 a o a I m m as af EE Motor Motor N Ls Cables Cables Meg o dE e he HF Ap B o Q o T nE i J o Ba Ground a f oo o o o a P oO 0 Q Input Power a u aii Cables a o a El e Ih ollo p e ah o ke x x Input aaa oe Ga Power pielej Cables 3 o VERE nN Standard Configuration B3 Motor Cables Input Power Ground Cables Ground UL Type 3R Configuration B1 B2 Note Type 3R enclosures are designed to be mounted on a wall For 3R enclosure back plates which maintain 3R integrity when the enclosure is mounted on an open rack system contact your ABB HVAC Drives Distributor ACH550 E Clipse Bypass 46 ACH550 Installation Operation and Maintenance Manual WARNING Check the motor and motor wiring insulation before connecting the ACH550 to line power Follow the procedure on page 12 Before proceeding with the insulation resistance measurements check that the ACH550 is disconnected from incoming line power Failure to disconnect line power coul
2. EVPASS CONTROL F ENTER ENSELED Q 5 SELECTED gt AND Y FT j DENE 1 MOTER RUN H l S in Om is S ar i S I S CNA Si Wy a iS Is is Si gt EIA 485 port control terminals 47 Basic connections The figure on page 52 shows the basic control connections for use with the E Clipse Bypass HVAC Default macro These connections are described in the following paragraphs In typical installations only analog input wires connect to the ACH550 terminal block with other control connections made on the E Clipse Bypass control board Use wire ties to permanently affix control communications wiring to the hooked wire race tie points provided maintaining a minimum 6 mm 1 4 spacing from power wiring The following tables list power and motor cable terminal sizes for connections to an input circuit breaker or disconnect switch a motor terminal block and ground lugs The tables also list torque that should be applied when tightening the terminals ACH550 E Clipse Bypass 48 Vertical enclosure terminals ACH550 Installation Operation and Maintenance Manual
3. Output or Circuit Breaker Ground Lug s Input Output Ground Lug Terminals B Input Power 4 Service Switch Cable Optional Terminals BP0054 ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 41 Connection diagrams Standard E Clipse Bypass wall mounted ACH550 Standard E Clipse Bypass units are configured for wiring access from the top The following figure shows the Standard E Clipse Bypass wall mounted wiring connection points ACH550 User Power Cable Guides NYY mr an E Clipse Bypass Control Board Terminals X2 Service Switch Optional Motor Terminals Output Ground Lug Disconnect Switch or Circuit Breaker Input Power Terminals Input Ground Lug s ACH550 E Clipse Bypass 42 ACH550 Installation Operation and Maintenance Manual ae User PowerCable Guides eee ACH550 Drive oe ge E Clipse Bypass Control Board a ar aaa Terminals X2 Disconnect Switch ar or Circuit Breaker Lae Input Ground Lug ye H RA a rey TI TI TT g i
4. Frame Maximum Wire Size Capacities of Power Terminals HP Identification Size Circuit Disconnect Motor Ground Breaker Switch Termination Lugs 208 240 Volt 1 ACH550 VxR 04A6 2 R1 1 5 ACH550 VxR 06A6 2 R1 ACH550 VxR 07A5 2 R1 71 0 i 35 in lbs 7 in lbs 6 4 ACH550 VxR 012A 2 R1 30 in Ibs 35 in lbs ACH550 VxR 017A 2 R1 8 7 5 ACH550 VxR 024A 2 R2 i 40 in lbs 8 7 in lbs 2 10 ACH550 VxR 031A 2 R2 2 50 in lbs 15 ACH550 VxR 046A 2 R3 50 in lbs 4 2 20 ACH550 VxR 059A 2 R3 18 in lbs 2 0 50 in lbs 1 120 in lbs 25 ACH550 VxR 075A 2 R4 50 in lbs 55 in lbs 380 480 Volt 1 1 5 ACH550 VxR 03A3 4 R1 2 ACH550 VxR 04A1 4 R1 1 1 3 ACH550 VxR 06A9 4 R1 35 in lbs 7 in lbs 6 4 5 ACH550 VxR 08A8 4 R1 gt 30 in lbs 35 in lbs 7 5 ACH550 VxR 012A 4 R1 10 ACH550 VxR 015A 4 R2 8 15 ACH550 VxR 023A 4 R2 40 in Ibs y ee 20 ACH550 VxR 031A 4 R3 25 ACH550 VxR 038A 4 R3 i i 50 in lbs 4 50 in lbs 30 ACH550 VxR 045A 4 R3 18 in lbs 40 ACH550 VxR 059A 4 R4 2 ry 50 in lbs 50 ACH550 VxR 072A 4 R4 1 55 in lbs 2 0 50 in lbs 120 in lbs 1 60 ACH550 VxR 078A 4 R4 i 70 in lbs ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 49 frame Maximum Wire Size Capacities of Power Terminals HP Identification Size Circuit Disconnect
5. Input Power Terminals Motor Terminals Output Ground Lug ie ore Service Switch optional B2 B2 ACH550 Drive Output Ground Lug Input Ground Lug Motor Terminals Input Power Terminals olol EES T E afc z a E Clipse Bypass Control Board Terminals X2 Service Switch optional ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 43 Connection diagrams Standard E Clipse Bypass R8 floor mounted ACH550 Standard E Clipse Bypass units are
6. Power Input U1 V1 W1 Power Output to Motor U2 V2 W2 page 70 WARNING To avoid danger or damage to the drive on IT systems and corner grounded TN systems see section Disconnecting the internal EMC filter on ACH550 UH 10 ACH550 Installation Operation and Maintenance Manual R7 R8 Similar A Ground Lug ACH550 Control Wires Terminals Bar X1 Input Power Terminals Terminal Strip Only on ACH550 UH Disconnecting the internal EMC filter On certain types of systems you must disconnect the internal EMC filter otherwise the system will be connected to ground potential through the EMC filter capacitors which might cause danger or damage the drive Note When the internal EMC filter is disconnected the drive is not EMC compatible The following table shows the installation rules for the EMC filter screws in order to connect or disconnect the filter depending on the system type and the frame size For more information on the different system types see Floating networks on page 12 and Unsymmetrically grounded networks on page 11 The locations of screws EM1 and EM3 are shown in the diagram on page 8 The locations of screws F1 and F2 are shown in the diagram on page 9 Symmetrically IT systems ungrounded pr Screw grounded TN systems a e or high resistance TN S systems
7. 1 PxR represents both PCR and PDR 2 Torque values shown relate to current production Check component labels on previously installed units for required tightening torque ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 83 600 Volt Power Wiring Data Circuit Ata Disconnect Disconnect Ground Ground Frame Breaker Switch Switch ici Lugs Lugs HP Type Code Size UL Type ae UL Type UL Type Te kao UL Type UL Type NEMA Nma NEMA NEMA NEMA NEMA 1 amp 12 3R 1 amp 12 3R 1812 3R 2 ACH550 PxR 02A7 6 R2 3 ACH550 PxR 03A9 6 R2 5 ACH550 PxR 06A1 6 R2 6 6 6 6 7 5 ACH550 PxR 09A0 6 R2 62in lbs 62 in lbs 8 8 Powe SSI IDS 10 ACH550 PxR 011A 6 R2 7 in lbs 7 in Ibs 15 ACH550 PxR 017A 6 R2 20 ACH550 PxR 022A 6 R3 3 3 3 3 25 ACH550 PxR 027A 6 R3 62in lbs 62in lbs ee Beh eon les 30 ACH550 PxR 032A 6 R4 i pi Drive s power 40 ACH550 PxR 041A 6 R4 18 in Ibs 18 in Ibs connection terminals 1 1 1 41 2 50 ACH550 PxR 052A 6 R4 62in lbs 62in lbs 55 in lbs 55 in lbs 50 in Ibs i 1 1 50 in lbs 60 ACHS550 PxR 062A 6 R4 ab bs Pesce 75 ACH550 PxR 077A 6 R6 1 0 1 0 100 ACH550 PxR A R 70 in lbs 70 in lbs Auer 350 MCM 300 MCM 3 x 3 0 PxR 125A in in 250 in lb 125 ACHS50 PxR 125A 6 R6 274 in lbs 275 in lbs 359 MCM Z
8. Customer Auto Start Digital Input 1 Parameter 1601 START STOP Digital Input 2 Parameter 1602 06 NOT SEL Digital Input 3 Parameter 1603 START EN 1 Safety interlock 1 Digital Input 4 Parameter 1604 07 NOT SEL Digital Input S Parameter 1605 1701 NOT SEL Digital input Fixed SMOKE CONTROL Override 1 Firestat Freezestat High Static Switch Relay Output 1 Parameter 1401 BYP NOT FLT Default Operation Sypass Not faulted 11 connected to 13 Bypass Faulted 11 connected to 12 Relay Oulput2 Parameter 1404 SYS RUNNING Default Operation System Running 14 connected to 16 Relay Oulput3 Parameter 1407 SYS STARTED Default Operation System Started 17 connected to 19 Relay Outputs Parameter 1410 BYPASS SEL Default Operation Sypass Selected 20 connected to 22 Relay Output5 Parameter 1413 BYPASS AUTO Defaut Operation Sypass In Auto 23 connected to 25 Parameters Changed Relative to E Clipse HVAC Default Parameter Number Description Setting Smoke Control Override1 is a fixed input Closing Digital Input 6 will place the E Clipse Bypass in Smoke Control mode which may reassign the function of the other Digital Inputs Refer to the Smoke Control Override1 documentation ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 53 2 Check installation bypass Control panel se
9. low input voltage 4006 Selected by PAR Alarm will occur when Run Enable conditionis Check 24 Volts on 1620 start order is given and not satisfied RBCU unit RUN ENABLE the Hine Enable isnot Bad 24v supply Check for 24 volts on DAMPER END presen Bad digital input respective DI when SWITCH condition is satisfied VALVE OPENING Check Parameter 01 03 PRE LUBE CYCLE for status of digital input 4007 PCB TEMP RBCU unit reached Cabinet cooling has Stop drive and let cool 181 degrees failed down and restart Coe 83 degrees Ambient conditions too Add additional cooling PRE high Replace RBCU Bad RBCU unit 4008 DRIVE SETUP Alarm generated when Incorrect parameters Set Parameter 1001 to configuration of drive is settings COMM such that bypass can Set Parameter 1002 to not properly control the COMM drive Specifically drive Set Parameter 1601 to parameters COMM 1001 1002 1601 1608 Set Parameter 1608 to COMM 4009 BYPASS RUN Alarm is generated NA NA DELAY when a bypass start command is issued and there is non zero time value in bypass parameter 1614 4010 MTR OVERLOAD Bypass warning if Drive Mode Drive Mode ee ioe Bad Motor Refer to 550 manual conditions exist as j for proper defined in the drive PONGE troubleshooting Bad RBCU techniques Bypass mode Bypass Mode Bad motor Check that J2 Bad CT s connector is firmly Bad RBCU seated in RBCU Either mode Check input voltage Does overload condi
10. Note Frame sizes R3 and R4 have four holes along the top Use only two If possible use the two outside holes to allow room to remove the fan for maintenance Note ACH400 drives can be replaced using the original mounting holes For R1 and R2 frame sizes the mounting holes are identical For R3 and R4 frame sizes the inside mounting holes on the top of ACH550 drives match ACH400 mounts ACH550 UH 2 ACH550 Installation Operation and Maintenance Manual Note Frame sizes R7 and R8 have mounting holes inside the enclosure base Where it is not possible to use either mounting hole at the back of the base use an L bracket at the top of the enclosure to secure the cabinet to a wall or to the back of another enclosure Bolt the L bracket to the enclosure using the lifting lug bolt hole on the top of the enclosure Drill holes of appropriate size in the mounting location 3 Remove front cover R1 1 R6 UL type 1 Remove the control panel if attached 2 Loosen the captive screw at the top 3 Pull near the top to remove the cover R1 a oe R7 4 Mount the drive R1 R6 UL type 1 1 R6 UL type 12 If hood is present Remove screws 2 holding the hood in place If hood is present Slide hood up and off of the cover Loosen the captive screws around the edge of the cover Remove the cover R8 Cabinet Door To open the cabinet door loosen the quarter
11. Remove the screws attaching the fan e R5 Swing the fan out on its hinges Bottom View R6 e R6 Pull the fan out Disconnect the fan cable Restore power X0022 Frame Sizes R7 and R8 Refer to the installation instructions supplied with the fan kit ACH550 UH 34 ACH550 Installation Operation and Maintenance Manual Enclosure fan replacement UL Type 12 enclosures UL type 12 enclosures include an additional fan or fans to move air through the enclosure Frame Sizes R1 to R4 To replace the internal enclosure fan in frame sizes R1 to R4 1 Remove power from drive 2 Remove the front cover 3 The housing that holds the fan in place has barbed retaining clips at each corner Press all four clips toward the center to release the barbs 4 When the clips barbs are free pull the housing up to remove from the drive 5 Disconnect the fan cable 6 Install the fan in reverse order noting that e The fan air flow is up refer to arrow on fan e The fan wire harness is toward the front e The notched housing barb is located in the right rear corner e The fan cable connects just forward of the fan at the top of the drive Frame Sizes R5 and R6 To replace the internal enclosure fan in frame sizes R5 or R6 e Remove power from drive e Remove the front cover e Lift the fan out and
12. enclosure Back of Enclosure Mounting ___ gt Screw Filter Bracket Enclosure ACH550 PCR PDR 88 ACH550 Installation Operation and Maintenance Manual 3 Lift the filter out of the filter bracket and replace as appropriate 4 With the filter in the filter bracket align the hooks on the bracket with the slots in the enclosure base and press the hooks up into the slots 5 Slide the filter bracket back making sure that the hooks catch on the enclosure 6 Replace the mounting screw Tighten until the gasket on the bracket is about 50 compressed Enclosure air filter replacement UL Type NEMA 12 floor mount enclosures Filter material Enclosure Type Inlet door Outlet roof UL Type NEMA 12 3AUA0000006723 qty 1 3AUA0000006722 qty 2 Note When installing the filter media the white side must face the outside of the cabinet and the colored side must face the inside of the cabinet Refer to page 34 Diagnostics Refer to the Diagnostics instructions on page 24 3AUA0000081824 REV A Effective 08 01 2010 ABB Inc 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 1 800 752 0696 Fax 1 262 785 0397 Internet www abb us drives
13. y grounded gt 30 ohm EM1 x x e R1 R3 EM3 X e e EM1 x x R4 EM3 X F1 xX x R5 R6 F2 x x x Install the screw EMC filter will be connected e Replace the screw with the provided polyamide screw EMC filter will be disconnected Remove the screw EMC filter will be disconnected EM1 and EMS screws are M4 x 12 F1 and F2 screws are M4 x 16 ACH550 UH ACH550 Installation Operation and Maintenance Manual Ground connections 17 For personnel safety proper operation and to reduce electromagnetic emission pick up the drive and the motor must be grounded at the installation site e Conductors must be adequately sized as required by safety regulations e Power cable shields must be connected to the drive PE terminal in order to meet safety regulations e Power cable shields are suitable for use as equipment grounding conductors only when the shield conductors are adequately sized as required by safety regulations e In multiple drive installations do not connect drive terminals in series Unsymmetrically grounded networks A WARNING Do not attempt to install or remove EM1 or EM3 screws while power is applied to the drive s input terminals Unsymmetrically grounded networks are defined in the following table In such networks the internal connection provided by the EM3 screw on frame sizes R1 R4 only must be disconnected by removing EM3 If the grou
14. 3902 Follow DriveLink recovery procedure 3020 PHASE SEQ Sequence of 3 phase Phase sequence Swap any two of the voltage input is such unknown at time of three input wires to the that bypass operation wiring bypass unit will result in motor rotation opposite of drive forward operation 3021 PH A CURR FBK Fault is generated Loose CT connection Check J2 connector when current in Phase Bad RBCU for proper seating A is detected and the Bad CT Check connector on bypass contactor is Current Assembly open Replace RBCU Replace RCSA unit 3022 PH C CURR FBK Fault is generated Loose CT connection Check J2 connector when current in Phase Bad RBCU for proper seating C is detected and the Bad CT Check connector on bypass contactor is Current Assembly Open Replace RBCU Replace RCSA unit ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 69 Fault Fault Name In z Code Panel Fault Possible Cause Corrective Action 3023 BYP COIL Coil characteristics Shorted contactor coil Replace RBCU SHORTED are checked only on Shorted damaged Replace RCSA unit power up and coil cable current is greater than allowable values Bad RBCU 3024 DRV COIL Coil characteristics Shorted contactor coil Replace RBCU SHORTED are checked only on Shorted damaged Replace RCSA unit power up and coil cable current is greater than allowable values Bad RBCU 3027 INVALID SUB Contactor assembly RBCU
15. 4 EDIT to change the parameter value Press the UP DOWN buttons to change the parameter value CDA EP id CDa GF Select SAVE to store the modified value or select CANCEL to leave the set mode 6 Any modifications not saved are cancelled al Select EXIT to return to the listing of parameter groups and again to return to 4 7 the main menu w4 Complete the control connections by manually entering the parameters Note The current parameter value appears below the highlighted parameter To view the default parameter value press the UP DOWN buttons simultaneously To restore the default factory settings select the application macro HVAC Default ACH550 UH 24 Diagnostics Fault listing ACH550 Installation Operation and Maintenance Manual Fault Code Fault Name In Panel Description and Recommended Corrective Action 1 OVERCURRENT Output current is excessive Check for and correct e Excessive motor load e Insufficient acceleration time parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2 e Faulty motor motor cables or connections e Output disconnect device not interlocked e Interaction with external input filter DC OVERVOLT Intermediate circuit DC voltage is excessive Check for and correct e Static or transient overvoltages in the input power supply e Insufficient deceleration time parameters 2203 DECELER TIME 1 and 2206 DECELER T
16. BRK UDC Terminals Min Wire Size Max Wire Size Torque Max Wire Size Torque mim AWG mm AWG Nm lb ft mm AWG Nm lb ft R1Note1 0 75 18 16 13 J1 16 1 3 ff R2Note1 0 75 18 16 1 3 l1 16 1 3 1 RgNote1 2 5 14 25 27 2 25 27 2 R4Note1 10 8 50 1 0 5 6 4 50 1 0 5 6 4 R5 16 6 70 2 0 15 11 70 2 0 15 11 R6 g5Note2 3 0 185 350MCM 40 30 185 350 MCM 40 30 R7 16 6 185 350 MCM 40 30 Attach appropriate ring lugs to R8 16 6 2x240 2x500 MCM 57 42 ea a wn 1 Do not use aluminum cable with frame sizes R1 R4 2 See the following section for smaller wire sizes on frame size R6 Power terminal considerations R6 Frame size WARNING For R6 power terminals if compression lugs are supplied they can only be used for wire sizes that are 95 mm 3 0 AWG or larger Smaller wires will loosen and may damage the drive and require ring lugs as described below On the R6 frame size if the cable size used is less than 95 mm 3 0 AWG or if no compression lugs are supplied use ring lugs Drive s control connection terminals The following table provides specifications for the drive s control terminals Control Frame Size Maximum Wire Size Torque mm AWG Nm lb ft All 1 5 16 0 4 0 3 Control terminal descriptions The following full page diagram provides a general description of the control terminals on the drive Note Terminals 3 6 and 9 are
17. Contact your local ABB sales representative 22 SUPPLY PHASE Ripple voltage in the DC link is too high Check for and correct e Missing mains phase e Blown fuse e Interaction with external input filter Set parameter 2619 to ON 23 ENCODER ERR Not used Available only with encoder and parameter Group 50 23 ENCODER ERR The drive is not detecting a valid encoder signal Check for and correct e Encoder presence and proper connection reverse wired loose connection or short circuit e Voltage logic levels are outside of the specified range e A working and properly connected Pulse Encoder Interface Module OTAC 01 e Wrong value entered in parameter 5001 PULSE NR A wrong value will only be detected if the error is such that the calculated slip is greater than 4 times the rated slip of the motor e Encoder is not being used but parameter 5002 ENCODER ENABLE 1 ENABLED 24 OVERSPEED Motor speed is greater than 120 of the larger in magnitude of 2001 MINIMUM SPEED or 2002 MAXIMUM SPEED Check for and correct e Parameter settings for 2001 and 2002 e Adequacy of motor braking torque e Applicability of torque control e Brake chopper and resistor 25 RESERVED Not used as of the publication of this manual 26 DRIVE ID Internal fault Configuration Block Drive ID is not valid Contact your local ABB sales representative 27 CONFIG FILE Internal co
18. Motor Ground Breaker Switch Termination Lugs 500 600 Volt ACH550 VxR 02A7 6 R2 ACH550 VxR 03A9 6 R2 5 ACH550 VxR 06A1 6 R2 8 6 4 7 5 ACH550 VxR 09A0 6 R2 62 in lbs 8 30 in lbs 35 in lbs 10 ACH550 VxR 011A 6 R2 7 in lbs 15 ACH550 VxR 017A 6 R2 20 ACH550 VxR 022A 6 R3 4 2 25 ACH550 VxR 027A 6 R3 62 in lbs 50 in lbs 30 ACH550 VxR 032A 6 R4 4 40 ACH550 VxR 041A 6 R4 18 in lbs 2 1 H 2 0 50 in lbs 50 ACH550 VxR 052A 6 R4 62 in lbs 56 indbs 120 in lbs 60 ACH550 VxR 062A 6 R4 Hf 70 in lbs Standard enclosure terminals Frame Maximum Wire Size Capacities of Power Terminals HP Identification Size Circuit Disconnect Motor Ground Breaker Switch Termination Lugs 208 240 Volt 1 ACH550 BxR 04A6 2 R1 1 5 ACH550 BxR 06A6 2 R1 ACH550 BxR 07A5 2 R1 8 6 4 ACH550 BxR 012A 2 R1 40 in lbs ra 30 in lbs 35 in lbs ACH550 BxR 017A 2 R1 7 in Ibs 7 5 ACH550 BxR 024A 2 R2 2 10 ACH550 BxR 031A 2 R2 R3 50 in lbs 15 ACH550 BxR 046A 2 R3 a 4 le 50 in lbs i 2 50 in lbs 20 ACH550 BxR 059A 2 R3 18 in Ibs 120 in lbs 1 25 ACH550 BxR 075A 2 R4 56 in lbs ACH550 E Clipse Bypass 50 ACH550 Installation Operation and Maintenance Manual Erime Maximum Wire Size Capacities of Power Terminals HP Identification
19. Size Circuit Disconnect Motor Ground Breaker Switch Termination Lugs 208 240 Volt continued 1 0 1 30 ACH550 BxR 088A 2 R4 70 in lbs 53 in lbs 40 ACH550 BxR 114A 2 R4 350 MCM 250 MCM 50 ACH550 BxR 143A 2 R6 274 in lbs 300 MCM 300 in lbs 3 x 3 0 275 in lbs 250 in lbs 60 ACH550 BxR 178A 2 R6 oN M at 375 in lbs 75 ACHS50 BxR 221A 2 R6 2x250MCM 2x250MCM 2x 500 MCM 100 ACH550 BxR 248A 2 R6 274 in lbs 274 in lbs 375 in lbs 380 480 Volt 1 1 5 ACH550 BxR 03A3 4 R1 ACH550 BxR 04A1 4 R1 ACH550 BxR 06A9 4 R1 8 6 4 ACH550 BxR 08A8 4 R1 40 in lbs us 30 in lbs 35 in lbs 7 5 ACH550 BxR 012A 4 R1 7 in lbs 10 ACH550 BxR 015A 4 R2 15 ACH550 BxR 023A 4 R2 20 ACH550 BxR 031A 4 R3 25 ACH550 BxR 038A 4 R3 ip 4 50 in lbs 30 ACH550 BxR 045A 4 R3 A 18 in lbs 40 ACH550 BxR 059A 4 R4 1 2 50 in lbs H 50 in lbs 50 ACH550 BxR 072A 4 R4 2 0 55 in lbs 3 120 in lbs 1 60 ACH550 BxR 078A 4 R4 TER 70 in Ibs 1 0 1 75 ACH550 BxR 097A 4 R4 A 70 in Ibs 53 in Ibs 100 ACH550 BxR 125A 4 R5 350 MCM 250 MCM 125 ACH550 BxR 157A 4 R6 274 in lbs 300 MCM 300 in lbs 3 x 3 0 275 in lbs 250 in lbs 150 ACH550 BxR 180A 4 R6 a ae 375 in lbs 2 x 250 MOM 2x 250 MCM 2x 500 MCM 200 ACH550 BxR 246A 4 R6 274in lbs 274intbs 375 indbs 250 ACH550 BxR 316A 4 R8 5 Bus bar 300 ACH550 BxR 368A 4 R8 2x500MCM 2x500MCM 2x 600 MCM holes 350 ACH550 BxR 414A 4 R8 274 in lbs 275 in lbs 500 in lb
20. cables through the conduit and control cables to the box separate conduits the drive terminals IP2004 Note For R5 frame size the minimum power cable size is 25 mm 4 AWG For R6 frame size refer to Power terminal considerations R6 Frame size on page 16 not the same conduit as either input power or motor wiring Use available secure points and tie strap landings to permanently secure control wiring at a minimum distance of 6 mm 1 4 from power wiring Strip the control cable sheathing and twist the copper screen into a pig tail Connect the ground screen pig tail for digital and analog I O cables at X1 1 Ground only at drive end Connect the ground screen pig tail for RS485 cables at X1 28 or X1 32 Ground only at drive end ai Strip and connect the individual control wires to the drive terminals Install the conduit box cover 1 screw ACH550 UH 14 ACH550 Installation Operation and Maintenance Manual R1 R6 wiring UL type 12 enclosure 1 3 Route the power wiring through conduit 4 Route the motor wiring through conduit not the 5 Strip the wires 10 11 12 13 Step depends on Frame Size e Frame Sizes R1 R4 Remove and discard the cable seals where conduit will be installed The cable seals are cone shaped rubber seals on the bottom of the drive IP5013 e Frame Sizes R4 and R5 Use punch to create holes for conduit connections as
21. configured for wiring access from the top The following figure shows the Standard E Clipse Bypass floor mounted wiring connection points Ground Lug Bar ACH550 Drive Motor Terminals Input Power Terminals E Clipse Bypass eo a ii Control Board lt Hy Terminals x2 ee i Disconnect Switch or Circuit Breaker Service sae F optional ACH550 Control Board Terminals x1 B4 ACH550 E Clipse Bypass 44 ACH550 Installation Operation and Maintenance Manual Power connections Vertical E Clipse Bypass configurations Line input connections Connect the input power to the terminals at the bottom of the disconnect switch or circuit breaker as shown below Also see Connection diagrams Vertical E Clipse Bypass on page 40 Connect the equipment grounding conductor to the ground lug near the input power connection point Motor Cables Motor connections iat Connect the motor cables to the terminals ineteewer at the bottom of the bypass section as Cables shown in the figure Also see Connection diagrams Vertical E C
22. disconnect switch or circuit breaker is closed and control power is applied to the bypass Enabled LED The Enabled LED is illuminated green under the following conditions e Both the Safety Interlock s and Run Enable contacts are closed e The Safety Interlock contact s are closed with no Start command present The Enabled LED flashes green if the Run Enable contact is open and when the Safety Interlock contact s are closed and a Start command is present The Enabled LED is illuminated red when the Safety Interlock contact s are open ACH550 E Clipse Bypass 62 ACH550 Installation Operation and Maintenance Manual Motor Run LED The Motor Run LED is illuminated green when the motor is running in either bypass mode or in drive mode The Motor Run LED flashes green to indicate the system has been placed in an Override condition Bypass Faulted LED The Bypass Faulted LED is illuminated or flashes red when the motor or bypass protection functions have shut down the bypass The specific nature of the fault is indicated on the bypass control display Refer to the Diagnostics section of this manual for more details Drive Selected LED The Drive Selected LED is illuminated green when the drive has been selected as the power source for the motor and no drive fault is present Bypass Selected LED The Bypass Selected LED is illuminated or flashes green when the bypass has been selected as the power source for the motor and no b
23. disconnect the cable e Install the fan in reverse order e Restore power Frame Sizes R7 R8 UL type 12 enclosures The enclosure fan is located in the exhaust box on top of the UL type 12 enclosure 1 Remove the left and right filter frames of the exhaust fan box by lifting them upwards z NNN 2 Disconnect the fan s electrical connector from the cabinet roof top right inside the cabinet i ACH550 UH ACH550 Installation Operation and Maintenance Manual 35 3 Undo the four fastening screws at the corners of the fan frame The screws are through bolts with nuts on the inside of the cabinet Do not drop the hardware into the drive PC00014 ase PC00017 4 Remove the fan and fan frame as one unit 5 Disconnect the fan wiring and capacitor from the fan frame Then remove the four screws attaching the fan to the fan frame Remove the old fan PC00020 6 Install the new fan and capacitor with the replacement part for ABB in the reverse order of the above Ensure the fan is centered on the Velocity velocity stack and rotates freely Stack Capacitor PC00014 Enclosure air filter replacement UL Type 12 enclosures Frame Sizes R7 R8 UL type 12 enclosure inlet air filter The inlet air filter for the R7 R8 UL type 12 enclosure is located in the enclosure front door 1 While holding the top of the filter frame pull up on the bottom of the frame Th
24. e Frame sizes R7 R8 pallet truck and hoist e For installations involving frame size R6 R8 The appropriate crimping tool for power cable lugs ACH550 UH ACH550 Installation Operation and Maintenance Manual 5 e Mounting hardware screws or nuts and bolts four each The type of hardware depends on the mounting surface and the frame size Frame Size Mounting Hardware Note R1 R4 M5 10 R5 M6 1 4 in R6 M8 5 16 in R7 R8 M10 7 16 Secures free standing cabinets if required e For installations involving frame size R7 R8 Hoist WARNING Before installing the ACH550 ensure the input power supply to the drive is off WARNING Metal shavings or debris in the enclosure can damage electrical equipment and create a hazardous condition Where parts such as conduit plates require cutting or drilling first remove the part If that is not practical cover nearby electrical components to protect them from all shavings or debris Flange Mounting Instructions Framesi IP21 UL type 1 IP54 UL type 12 Kit Code English Kit Code English R1 FMK A R1 100000982 FMK B R1 100000990 R2 FMK A R2 100000984 FMK B R2 100000992 R3 FMK A R3 100000986 FMK B R3 100000994 R4 FMK A R4 100000988 FMK B R4 100000996 R5 AC8 FLNGMT R5 ACS800 PNTG01U EN R6 AC8 FLNGMT R6 2 Prepare the mounting location 1 Mark the position of the mounting holes
25. from the top of the left bay 2 Route the input power motor and control cables to the top of the cabinet Each cable type input power motor and control must Input Power be in separate conduit Cable a ee 3 Use punch to create holes for conduit connections as needed Terminal Strip Only on 4 UL type 12 Enclosure For each conduit ACH550 UH run input power motor and control wiring must be separate install water tight conduit connectors not supplied BP0054 5 Connect input power and motor cables to the bus terminals 6 Connect grounds to ground bar 7 Use available secure points and tie strap landings to permanently secure control Cable wiring at a minimum distance of 6 mm 1 4 from power wiring 8 Strip the control cable sheathing and twist the copper screen into a pig tail 9 Connect the ground screen pig tail for digital and analog I O cables at X1 1 Ground only at drive end 10 Connect the ground screen pig tail for BP0054 RS485 cables at X1 28 or X1 32 Ground l only at drive end 11 Strip and connect the individual control wires to the drive terminals ACH550 UH Drive s power connection terminals ACH550 Installation Operation and Maintenance Manual The following table provides specifications for the drive s power connection terminals U1 V1 W1 Frame U2 V2 W2 Earthing PE Terminal Size
26. needed IP5023 For each conduit run input power motor and control wiring must be separate install water tight conduit connectors not supplied IP5006 same conduit as input power wiring run Connect the power motor and ground wires to the drive terminals Note For R5 frame size the minimum power cable size is 25 mm 4 AWG For R6 frame size refer to Power terminal considerations R6 Frame size on page 16 Route the control cables through the conduit not z A the same conduit as either input power or motor wiring runs Use available secure points and tie strap landings to 9 11 permanently secure control wiring at a minimum distance of 6 mm 1 4 from power wiring Strip the control cable sheathing and twist the copper screen into a pig tail Connect the ground screen pig tail for digital and analog I O cables at X1 1 Ground only at drive end Connect the ground screen pig tail for RS485 cables at X1 28 or X1 32 Ground only at drive end Strip and connect the individual control wires to the drive terminals Install the conduit box cover 1 screw IP5008 ACH550 UH ACH550 Installation Operation and Maintenance Manual 15 R7 R8 wiring both enclosure types The figures show connections in the R7 cabinet the R8 cabinet is similar 1 Remove the conduit connection plate
27. on RBCU for tightness of A1 and A2 terminals Bad Contactor Swap RBCU Change Contactor Assembly 3006 UNDERVOLTAGE Message only occurs Loose J7 connector Check that J7 if drive is controlling on RBCU unit connector is firmly the motor and the Loose input wiring seated in RBCU power to the bypass is Check tightness of removed before the Incoming power ap eee a ti problems coming connections drive phases back Check P Message will appear eck Parameter in the fault log This 0413 to view voltage message will only level at time of trip appear when drive Check upstream contactor opens when protection drive is operating 3008 DRIVE Al2 LOSS Only displayed when Check ACH550 Check ACH550 in Supervisory mode manual for Al2 loss manual for Al2 loss Indicates that Al2 on the drive has failed 3009 MTR OVERLOAD Bypass opens on Drive Mode Check if overload motor overload Bad Motor condition exists conditions defined in Bad CT s Drive Mode the drive Bad RBCU Refer to 550 manual B de for proper ypass moge troubleshooting Bad motor techniques Bad CT s Bypass Mode Bad RBCU Check that J2 Either mode connector is firmly low input voltage seated in RBCU Use clamp meter to verify mtr current vs display in parameter 0101 Check input voltage ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 67 arih ja enig In Fault Possible Cause Corrective Action 3010 INP
28. turn screws that hold the cabinet door closed R8 Side Panels The side panels were removed to take the cabinet off the pallet Installation access is easier if these panels are kept off throughout the installation Position the ACH550 onto the mounting screws or bolts and securely tighten in all four corners Note Use mounting hardware that permits fan replacement without removal Note Lift the ACH550 by its metal chassis IP2002 Non English speaking locations Add a warning sticker in the appropriate language over the existing warning on the top of the module ACH550 UH ACH550 Installation Operation and Maintenance Manual R1 As required for access remove the rubber plugs R6 UL type 12 For the UL type 12 enclosures rubber plugs are required in the holes provided for access to the drive mounting slots Push plugs out from the back of the drive R5 amp R6 Align the sheet metal hood not shown in front of the drive s top mounting holes Attach as part of next step Position the ACH550 onto the mounting screws or bolts and securely tighten in all four corners Note Lift the ACH550 by its metal chassis frame size R6 by the lifting holes on both sides at the top 4 Re install the rubber plugs 5 Non English speaking locations Add a warning sticker in the appropriate language R7 Use a hoist to mov
29. 2 R2 6 6 8 8 6 6 10 ACH550 PxR 031A 2 R2 45 in lbs 45 in lbs 7 in lbs 7 in lbs 35 in lbs 35 in lbs 15 ACH550 PxR 046A 2 R3 3 3 4 4 3 3 20 ACH550 PxR 059A 2 R3 50 in lbs 50 in lbs 18 in lbs 18 in lbs pais N 50 in lbs 50 in lbs power 25 ACH550 PxR 075A 2 R4 A a fl f connection 50 in lbs 50 in lbs 55 in lbs 55 in lbs terminals 1 0 1 0 H ihe 30 ACH550 PxR 088A 2 R4 Snake ibg 50 in lbs 50 in lbs 40 ACHS50 PxR 1144 2 R4 350 som 300 MCM 50 ACH550 PxR 143A 2 R6 274 in lbs 200in Ibs 399 MCM 300 MCM 275 in lbs 200 in Ibs ais A z 2 275 in lbs 60 ACH550 PxR 178A 2 R6 3x 43 0 250 in lbs pt BERS ENE ee re He cM NGM 2X250MCM 2x 250 MCM 350 MCM 100 ACH550 PxR 248A 2 R6 274 in lbs_ 275 in lbs 274 in lbs 275 in lbs 100 in lbs 1 PxR represents both PCR and PDR 2 Torque values shown relate to current production Check component labels on previously installed units for required tightening torque ACH550 PCR PDR 82 ACH550 Installation Operation and Maintenance Manual 480 Volt Power Wiring Data Base E A Disconnect Disconnect Ground Ground ae Ge Gi Switch Switch ister Lugs Lugs 1 HP Type Code SI Type Type UL Type UL Type terminals UL Type UL Type ee EMA NENA NEMA NEMA NEMA NEMA 1812 3R 1 amp 12 3R 1812 3R 1 1 5 ACH550 Px
30. 230 F Check for and correct e Fan failure e Obstructions in the air flow e Dirt or dust coating on the heat sink e Excessive ambient temperature e Excessive motor load 2010 MOT OVERTEMP Motor is hot based on either the drive s estimate or on temperature feedback This alarm warns that a Motor Underload fault trip may be near Check e Check for overloaded motor e Adjust the parameters used for the estimate 3005 3009 e Check the temperature sensors and Group 35 parameters 2011 UNDERLOAD Motor load is lower than expected This alarm warns that a Motor Underload fault trip may be near Check e Motor and drive ratings match motor is NOT undersized for the drive e Settings Group 37 USER LOAD CURVE 2012 MOTOR STALL Motor is operating in the stall region This alarm warns that a Motor Stall fault trip may be near 2013 note 1 AUTORESET This alarm warns that the drive is about to perform an automatic fault reset which may start the motor e To control automatic reset use parameter Group 31 AUTOMATIC RESET 2014 note 1 AUTOCHANGE This alarm warns that the PFA autochange function is active e To control PFA use parameter Group 81 PFA CONTROL 2015 PFA INTERLOCK This alarm warns that the PFA interlocks are active which means that the drive cannot start the following e Any motor when Autochange is used e The speed regulated motor when Autoch
31. 27 RO3B 1 Digital input impedance 1 5 kQ Maximum voltage for digital inputs is 30 V 2 Default values depend on the macro used Values specified are for the HVAC default macro ACH550 UH 18 ACH550 Installation Operation and Maintenance Manual You can wire the digital input terminals in either a PNP or NPN configuration PNP connection source NPN connection sink x1 X1 10 24V 10 24V 11 GND 4 M1 GND L12 DCOM 12 DCOM 13 DI1 13 DI1 14 DI2 14 Di2 15 DI3 15 DI3 16 DI4 16 DI4 17 DI5 17 DI5 18 DI6 18 DI6 Serial communications Terminals 28 32 provide RS485 serial communication connections used to control or monitor the drive from a fieldbus controller 6 Check installation Before applying power perform the following checks Check Installation environment conforms to the drive s specifications for ambient conditions The drive is mounted securely Space around the drive meets the drive s specifications for cooling The motor and driven equipment are ready for start For floating networks R1 R6 The internal RFI filter is disconnected screws EM1 amp EM3 or F1 amp F2 The drive is properly grounded The input power voltage matches the drive nominal input voltage range The input power connec
32. 4 V Aux Voltage Output X1 Relay Outputs Illustration of available switch positions not default settings J2 DIP Switches for RS485 Termination J2 J2 A A ON ON Optional Module 1 X1 Communications RS485 Optional Module 2 off position on position Power Input Power Output to Motor Frame Sizes U1 V1 W1 U2 V2 W2 R5 R6 differ See next page EM3 EM1 GND X0003 Terminals Not Used WARNING To avoid danger or damage to the drive on IT systems and corner grounded TN systems see section Disconnecting the internal EMC filter on page 10 ACH550 UH ACH550 Installation Operation and Maintenance Manual R5 wy 9 OE Lees i BE PE r Es a GND X0011 7 GND Power Input Power Output to Motor U1 V1 W1 U2 V2 W2 F1 Terminals Not Used g CJ Terminals Not Used aoe nao O fLieahnheakaaa
33. ACH550 Installation Operation and Maintenance Manual I O amp M ACH550 UH HVAC Drives 1 550 HP ACH550 BCR BDR VCR VDR E Clipse Bypass Drives 1 400 HP ACH550 PCR PDR Packaged Drives with Disconnect 1 550 HP Safety Use of warnings and notes ACH550 Installation Operation and Maintenance Manual There are two types of safety instructions throughout this manual e Notes draw attention to a particular condition or fact or give information on a subject e Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment They also tell you how to avoid the danger The warning symbols are used as follows Electricity warning warns of hazards AN from electricity which can cause physical injury and or damage to the equipment e WARNING The ACH550 adjustable speed AC drive should ONLY be installed by a qualified electrician WARNING Even when the motor is stopped dangerous voltage is present at the power circuit terminals U1 V1 W1 L1 L2 L3 and U2 V2 W2 T1 T2 T3 and depending on the frame size UDC and UDC or BRK and BRkK e WARNING Dangerous voltage is present when input power is connected After disconnecting the supply wait at least 5 minutes to let the intermediate circuit capacitors discharge before removing the cover e WARNING Even when power is switched off from the input terminals of the ACH550 there may be dangerous vo
34. DIT Try to request default value press UP and DOWN buttons simultaneously for NO DEFAULT a parameter which is defined not to have a default value Should not be possible when changing parameters from control panel 10 CAN T EDIT Parameter system is busy e g application macro change is in process at the TRY AGAIN same time when someone is trying to save a value for a parameter Should not be possible when changing parameters from control panel Maintenance See Maintenance for the ACH550 UH on page 37 ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 77 ACH550 PCR PDR Installation A A This information is unique to ACH550 input disconnect configurations PCR or PDR The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker Refer to the Installation instructions on page 3 for all other information Failure to observe the warnings and instructions may cause a malfunction or personal hazard WARNING Before you begin read Safety on page 2 WARNING When the ACH550 with Input Disconnect is connected to the line power the Motor Terminals T1 T2 and T3 are live even if the motor is not running Do not make any connections when the ACH550 with Input Disconnect is connected to the line Disconnect and lock out power to the drive before servicing the drive Failure to disconnect power may cause serious injury or deat
35. E Clipse Bypass ACH550 Installation Operation and Maintenance Manual Bypass status listing 75 Bypass Status 16 Characters Condition Description DRIVE BYPASS DRIVE SELECTED Displays which one is selected drive or BYPASS SELECTED bypass SAFETIES OPEN Displays if safeties START ENABLE 1 CLOSED and or START ENABLE 2 have been applied or if they are missing RUN PERMISSIVES OPEN Displays if RUN ENABLE is present or not CLOSED START REQUEST NOT PRESENT Displays if start request has been applied to PRESENT the system AUTO TRANSFER NOT TRANSFERRED Displays if the system is in Auto Transfer TRANSFERRED state or not Does not reflect to PAR 16 08 AUTO XFER value itself BYP OVERRIDE 1 NOT ACTIVATED Status of Override 1 ACTIVATED BYP OVERRIDE 2 NOT ACTIVATED Status of Override 2 ACTIVATED DRIVE FAULTED NO Displays if drive is faulted or not YES BYPASS FAULTED NO Displays if bypass is faulted or not YES SYSTEM STARTED NO Displays if system is started or not YES SYSTEM RUNNING NO Displays if system is running or not YES BYPASS ALARMS NO ALARMS Displays if there is an active alarm s in ALARM ACTIVE bypass or not HAND OFF AUTO OFF MODE Displays operating mode of the bypass HAND MODE OFF HAND or AUTO AUTO MODE ACH550 E Clipse Bypass 76 ACH550 Installation Operation and Maintenance Manual Error messages Error
36. FA ENABLE is activated 1009 PAR PCU1 Parameter values for power control are inconsistent Improper motor nominal frequency or speed Check for both of the following e 1 lt 60 9907 MOTOR NOM FREQ 9908 MOTOR NOM SPEED lt 16 e 0 8 lt 9908 MOTOR NOM SPEED 120 9907 MOTOR NOM FREQ Motor Poles lt 0 992 1010 PAR PFA Both the override mode and PFA are activated at the same time These OVERRIDE modes are mutually incompatible because PFA interlocks cannot be observed in the override mode 1011 PAR OVERRIDE Overeride is enabled but parameters are incompatible Verify that 1701 is PARS not zero and depending on 9904 value 1702 or 1703 is not zero 1012 PAR PFA IO 1 IO configuration is not complete not enough relays are parameterized to PFA Or a conflict exists between Group 14 parameter 8117 NR OF AUX MOT and parameter 8118 AUTOCHNG INTERV 1013 PAR PFA IO 2 IO configuration is not complete the actual number of PFA motors parameter 8127 MOTORS does not match the PFA motors in Group 14 and parameter 8118 AUTOCHNG INTERV 1014 PAR PFA IO 3 IO configuration is not complete the drive is unable to allocate a digital input interlock for each PFA motor parameters 8120 INTERLOCKS and 8127 MOTORS Fault history For reference the last three fault codes are stored into parameters 0401 0412 0413 For the most recent fault identified by parameter 0401 the drive stores additional data in pa
37. FF key on the bypass control panel causes the bottom line on the E Clipse Bypass display to indicate Off Stop For Steps 8 through 14 ACH550 Drive Parameter 9904 must be set to Scalar Freq After successful completion of Step 13 Parameter 9904 may be set to Vector Speed if very specific application requirements make it necessary to use this type of motor control Operation using the Vector Speed setting is unnecessary for control of almost all fan and pump applications Refer to the ACH550 UH User s Manual for details on setting parameters Press the Drive Select key on the E Clipse Bypass control panel The Drive Select LED should be illuminated Check to see that pressing the e Auto key on the bypass control panel causes the E Clipse Bypass display to indicate Bypass in Auto e Hand key on the bypass control panel causes no change to the E Clipse Bypass display e OFF key on the bypass control panel causes the E Clipse Bypass display to indicate Bypass in Off Press the HAND key on the drive control panel Note that the top line of the control panel display indicates HAND and run as a clockwise rotating arrow The Drive Run LED on the E Clipse Bypass control panel should be illuminated Press the UP arrow on the drive control panel Note that the speed reference indication in the top line of the drive control panel display increases from 0 0 SP In the middle line of the drive co
38. IME 2 e Verify that overvoltage controller is ON using parameter 2005 e Interaction with external input filter DEV OVERTEMP Drive heatsink is overheated Temperature is at or above limit R1 R4 amp R7 R8 115 C 239 F R5 R6 125 C 257 F Check for and correct e Fan failure e Obstructions in the air flow e Dirt or dust coating on the heat sink e Excessive ambient temperature e Excessive motor load SHORT CIRC Fault current Check for and correct e A short circuit in the motor cable s or motor e Supply disturbances RESERVED Not used DC UNDERVOLT Intermediate circuit DC voltage is not sufficient Check for and correct e Missing phase in the input power supply e Blown fuse e Undervoltage on mains All LOSS Analog input 1 loss Analog input value is less than AI1FLT LIMIT 3021 Check for and correct e Source and connection for analog input e Parameter settings for AI1FLT LIMIT 3021 and 3001 AIl lt MIN FUNCTION Al2 LOSS Analog input 2 loss Analog input value is less than AI2FLT LIMIT 3022 Check for and correct e Source and connection for analog input e Parameter settings for AI2FLT LIMIT 3022 and 3001 AI lt MIN FUNCTION ACH550 UH ACH550 Installation Operation and Maintenance Manual 25 Fault Code Fault Name In Panel Description and Recommended Corrective Action MOT TEMP Motor is too hot based on
39. M FREQ is negative when 8123 PFA ENABLE is active ACH550 UH 28 ACH550 Installation Operation and Maintenance Manual Fault Fault Name In ee Code Panel Description and Recommended Corrective Action 1002 RESERVED Obsolete 1003 PAR Al SCALE Parameter values are inconsistent Check for any of the following e 1301 Al 1 MIN gt 1302 Al 1 MAX e 1304 Al 2 MIN gt 1305 Al 2 MAX 1004 PAR AO SCALE Parameter values are inconsistent Check for any of the following e 1504 AO 1 MIN gt 1505 AO 1 MAX e 1510 AO 2 MIN gt 1511 AO 2 MAX 1005 PAR PCU 2 Parameter values for power control are inconsistent Improper motor nominal kVA or motor nominal power Check for the following e 1 1 lt 9906 MOTOR NOM CURR 9905 MOTOR NOM VOLT 1 73 Py lt 3 0 e Where Py 1000 9909 MOTOR NOM POWER if units are kW or Py 746 9909 MOTOR NOM POWER if units are HP e g in US 1006 EXT ROMISSING Parameter values are inconsistent Check for the following e Extension relay module not connected and e 1410 1412 RELAY OUTPUTS 4 6 have non zero values 1007 PAR Parameter values are inconsistent Check for and correct FBUSMISSING e A parameter is set for fieldbus control e g 1001 EXT1 COMMANDS 10 COMM but 9802 COMM PROT SEL 0 1008 PAR Parameter values are inconsistent 9904 MOTOR CTRL MODE must be 3 PFAWOSCALAR_ SCALAR SPEED when 8123 P
40. Message Description 1 CAN T EDIT Try to save value press the ENTER key in Parameter Edit State of a read PAR IS READ ONLY only parameter E g try to change value PAR 01 02 INPUT VOLT 2 CAN T EDIT Try to change value of a parameter which is allowed to be changed only when WHEN STARTED system is not started E g PAR 16 02 RUN ENABLE 3 CAN T EDIT Try to change value of a reset only parameter other than zero UP DOWN UP DOWN ONLY buttons must be pressed simultaneoulsy for requesting default value of the PAR on the display value zero and after that ENTER pressed for saving it reset the parameter E g PAR 04 01 LAST FAULT 4 CAN T EDIT Input voltage too low Changing of parameters prohibited since system cannot INP VOLTAGE LOW save values to nv mem w insufficient voltage 5 CAN T EDIT Try to save value press the ENTER key in Parameter Edit State of a hidden PAR IS HIDDEN parameter Should not be possible If hidden parameters are turned visible this message is not given 6 CAN T EDIT Try to save value which is over LO LIMIT of the parameter Should not be UNDER LO LIMIT possible when changing parameters from control panel 7 CAN T EDIT Try to save value which is over HI LIMIT of the parameter Should not be UNDER HI LIMIT possible when changing parameters from control panel 8 CAN T EDIT Try to save value which is out of enumerated value list Should not be possible ENUM VAL ONLY when changing parameters from control panel 9 CAN T E
41. OONEN 50 in lbs a 150 ACH550 PxR 144A 6 R6 275 in lbs 200 in Ibs 1 PxR represents both PCR and PDR 2 Torque values shown relate to current production Check component labels on previously installed units for required tightening torque ACH550 PCR PDR 84 ACH550 Installation Operation and Maintenance Manual UL Type NEMA 3R Enclosures I Input pe Power WARNING Check the motor and motor wiring insulation before connecting the ACH550 to line power Follow the procedure on page 12 Before proceeding with the insulation resistance measurements check that the ACH550 is disconnected from incoming line power Failure to disconnect line power could result in death or serious injury Note For the remainder of the wiring motor and control wiring refer to page 7 ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual Operation 85 This information is unique to ACH550 input disconnect configurations PCR or PDR Refer to the Operation instructions on page 27 for all other information Input disconnect configuration The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker and with a door interlocked external operating handle The operating handle can be padlocked in the OFF position padlock not supplied Enclosure options are UL Type 1 UL Type 12 and UL Type 3
42. PHASE A Fault will be generated Loose J7 connector Check J7 connector LOSS only when trying to Loose wiring on Check yellow wire on close the bypass Contactor assembly input block contactor and the RBCU does not sense Blown upstream fuse Check incoming voltage on Phase A voltage phase to ground 3011 INP PHASE B Fault will be generated Loose J7 connector Check J7 connector LOSS only when trying to Loose wiring on Check black wire on close the bypass Contactor assembly input block contactor and the RBCU does not sense Blown upstream fuse Check incoming voltage on Phase B voltage phase to ground 3012 INP PHASE C Fault willbe generated Loose J7 connector Check J7 connector LOSS only when trying to Loose wiring on Check red on input close the bypass Contactor assembly block contactor and the f RBCU does not Blown upstream fuse Check incoming senses voltage on voltage phase to Phase C ground 3013 DRIVE 1ST Fault generated if NA Run bypass unit in START attempting to close the drive mode before bypass contactor with attempting bypass out running the mode bypass in drive mode first 3014 COIL POW Coil power supply has Internal failure on Cycle power on SUPPLY failed to reach rated RBCU unit bypass unit If voltage Shorted contactor coil Contactor coil is shorted fault 3023 or 3024 will be generated If 3023 or 3024 is generated replace respective contactor If 3023 or 3024 is not generated on power up rep
43. R NEMA 1 NEMA 12 and NEMA 3R The following is a typical power diagram Disconnect Switch or Circuit Breaker Drive with Input Disconnect 3 Phase ACH550 Input Power 3 Drive 3 ACH550 PCR PDR 86 ACH550 Installation Operation and Maintenance Manual The following shows the front view of the ACH550 Drive with Input Disconnect standard configurations and identifies the major components UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 Vertical Construction Hinged Door Wall Mount Floor Mount Enclosures Enclosures Enclosures ACH550 Drive l N COO Control Panel Operating Handle for Disconnect Switch or Circuit Breaker UL Type NEMA 3R Enclosures ACH550 Drive Control Panel with Hinged Cover ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 87 Maintenance Maintenance intervals If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB for ACH550 enclosures in addition to the intervals on page 37 Maintenance Configuration Interval Instruction Check replace hinged Hinged door wall Check every 3 Enclosure air filter replacement door wall mount mount UL Type months Replace UL Type NEMA 12 hinged door enclosure inlet air filter NEMA 12 as needed wall mount enclosur
44. R 03A3 4 R1 2 ACH550 PxR 04A1 4 R1 10 10 10 10 10 10 3 AOSS FA OSA R1 35 in lbs 35 in lbs 7 in lbs 7 in lbs 35 in lbs 35 in lbs 5 ACHS550 PxR 08A8 4 R1 7 5 ACH550 PxR 012A 4 R1 10 ACH550 PxR 015A 4 R2 6 6 6 6 15 ACHS550 PxR 023A 4 Re 45in lbs 45 in lbs 8 8 35 in lbs 35 in lbs 7 in lbs 7 in lbs 20 ACH550 PxR 031A 4 R3 3 3 3 3 2 ACH550 PxR 3 CH Ex een R3 50 in lbs 50 in lbs 4 4 50 in Ibs 50 in Ibs 30 ACH550 PxR 045A 4 R3 is abs kre 40 ACH550 PxR 059A 4 R4 1 1 50 ACH550 PxR 072A 4 R4 1 1 i 50 in Ibs 50 in lbs __ 109S Suits 50 in lbs 50 in lbs PxR 7 1 1 Refer to 60 ACH550 PxR 078A 4 R4 50 in lbs 62 in Ibs Drive s 1 0 1 0 nect connection 75 ACH550 PxR 097A 4 R4 Ze be 76 rele terminale 2 A IN IDS 100 ACH550 PxR 125A 4 R5 350 MCM 300 MCM 125 ACHS550 PxR 157A 4 Re 2 4 Mlbs 200 in Ibs 309MCM 300MCM 3 x 3 0 210 275 in lbs 200 in lbs 250 in lbs 375 in lbs 150 ACH550 PxR 180A 4 R6 2 x 250 350 MCM 200 ACHS550 PxR 246A 4 R6 MCM 300 MCM 2x250 MEM 500 MCM 100 in Ibs 274 in lbs 274 in lbs 274 in lbs 274 in lbs 250 ACH550 PxR 316A 4 R8 2 x 500 300 ACH550 PxR 368A 4 R8 MCM 2 x 500 MCM 350 ACH550 PxR 414A 4 Re 274 in lbs 274 in lbs 5 Bus Bar 400 ACH550 PxR 486A 4 R8 Holes 450 ACH550 PxR 526A 4 R8 ore 18 32 X 500 ACH550 PxR 602A 4 R8 MCM 3x 400 MEM 375 in lbs g s inbs 550 ACH550 PxR 645A 4 R8
45. Refer to the ACH550 UH User s Manual for additional information Note Run motor from drive before attempting bypass operation System check motor connected to ACH550 with E Clipse Bypass After performing the control panel checks and setting the ACH550 Drive Start up Data parameters check the operation of the ACH550 Drive with E Clipse Bypass with the motor connected as follows 1 Disconnect and lock out power to the E Clipse Bypass unit wait at least five minutes before disconnecting power 2 Connect the motor to the output terminals CAUTION If the Bypass Override Override 2 input contact is closed the motor will start across the line as soon as power is applied If the Safety Interlock and Run Enable input contacts are closed and the Smoke Control Override 1 input contact is closed the motor will start across the line as soon as power is applied If the Start Stop Safety Interlock and Run Enable input contacts are closed and the system is in the Bypass mode and in either Hand or Auto the motor will start across the line as soon as power is applied If the Start Stop Safety Interlock and Run Enable input contacts are closed and the system is in the Drive mode with the drive in either Hand or Auto mode the motor will start on the drive as soon as power is applied In order to prevent the motor from starting the system should be in the Drive mode and the drive should be OFF when the power is disconnected at
46. TER VA aTe Select the appropriate Parameter Group with the Up Down arrows and press ENTER V A ENTER Select the appropriate Parameter in a group with the Up Down arrows and press ENTER V A ENTER Press the Up Down arrows to change the Parameter Value VA Press ENTER to store the modified value or press ESC to leave the Parameter Edit mode ENTER or ESC Press ESC to return to the listing of Parameter Groups and again to return to the Main Menu ESC ESC ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 65 9 Press ESC to return to the Default Display from the Main Menu ESC Note In the Parameter Edit mode the current parameter value appears below the parameter name Note To view the default parameter value press the Up Down arrows simultaneously Press Enter to restore the default parameter value or press ESC to leave the Parameter Edit mode Diagnostics Fault listing Fault Fault Name In n z Code Panel Fault Possible Cause Corrective Action 3001 COIL CURR FBK RBCU is sensing Defective component Change RBCU abnormal current on RBCU feedback when neither contactor should be energized 3002 BYP CNTACT M2 contactor indicates Defective Contactor Disconnect incoming STUCK it is not prepared to Defective RBCU power from unit move on a power up Check if contactor check of th
47. Volts on 1623 start order is given and not satisfied RBCU unit START ENABLE 3 the be Enable is not Bad 24v supply Check for 24 volts on VIBRATION a Bad digital input ropo ie DI m SWITCH BAN commoni not condition is satisfie x tied to Digital input Check Parameter 0103 LOW SUCTION common on bypass For status of digital PRES when using external 24 Input v supply 4024 Selected by PAR Alarm will occur when Run Enable condition is Check 24 Volts on 1624 start order is given and not satisfied RBCU unit START ENABLE 4 the ahah Enable isnot Bad 24v supply Check for 24 volts on VIBRATION vn Bad digital input eee ey SWITCH 24 Vcommon istot condition is satisfie tied to Digital input Check Parameter 0103 LOW SUCTION common on bypass For status of digital PRES when using external 24 Input v supply 4025 LOCAL DISABLED Alarm is displayed if MODE LOCK 16 29 is set to AUTO MODE and the Hand or Off key is pressed 4026 AUTO DISABLED This alarm is displayed if MODE LOCK 1629 is set to LOCAL MODE and the Auto key is pressed 4027 COMM CONFIG Alarm is displayed if the E Clipse parameters Change MAC address ERR drive and bypass MAC 5002 BP MAC ID amp to unique values addresses are equal or 5302 DV MAC ID are invalid set to the same value 4028 FBA PAR CONF Non embedded Verify Group 51 fieldbus has detected parameters an error in Group 51 parameters 4029 DRIVE FAULTED The drive is faulted Reset drive ACH550
48. ad 1 Set Parameter 9802 to STD MODBUS 2 Set Parameter 9902 to E CLIPSE 3 Cycle Power Following the above steps in order should restore proper communications between the ACH550 Drive and the E Clipse Bypass Should the E Clipse Keypad continue to display a Drive Link Fault Drive Link Error or Drive Setup alarm check the following parameter settings to ensure they have been recovered If necessary individually set the correct parameter settings as indicated below and cycle power The only ACH550 Drive macro that provides the proper configuration settings by default is the E Clipse Bypass macro If any other ACH550 Drive macro is used that macro should be selected after completing the initial tests When using any other macro the following ACH550 Drive parameter values must be set and power cycled or the E Clipse Bypass will not function properly e Parameter 9802 must be set to STD MODBUS e Parameter 1001 must be set to Comm e Parameter 1002 must be set to Comm e Parameter 1601 must be set to Comm ACH550 E Clipse Bypass 54 ACH550 Installation Operation and Maintenance Manual e Parameter 1608 must be set to Comm e Parameter 5303 must be set to 76 8 kb s e Parameter 5304 must be set to 8 EVEN 1 e Parameter 5305 must be set to DCU PROFILE e Parameter 5310 must be set to 103 e Parameter 5311 must be set to 104 e Power must be cycled
49. anel displays any other drive faults correct the fault condition before proceeding to the next step CAUTION Check motor rotation direction as soon as the motor begins to move If AN motor does not rotate in the correct direction shut down the drive disconnect and lock out power to the drive and wait five minutes Swap any two motor output wires T1 T2 and T3 Incorrect motor rotation direction may cause equipment damage 6 Increase the speed to 60 Hz or the highest safe operating speed 7 Press the OFF key on the drive control panel The motor should stop If the drive does not operate according to these steps refer to the ACH550 UH User s Manual If the drive operates according to these steps your ACH550 with E Clipse Bypass is ready to use with preset or modified macro settings Note The settings for ALL external serial communication between the ACH550 with E Clipse Bypass and any Building Automation System are configured using the E Clipse Bypass operator panel DO NOT attempt to configure the external serial communication connection using the ACH550 operator panel The settings for internal communication between the ACH550 and the E Clipse Bypass are configured at the factory and require no adjustment ACH550 E Clipse Bypass 56 ACH550 Installation Operation and Maintenance Manual Note Both the ACH550 Drive and the E Clipse Bypass include preset application macros The only ACH550 Drive macro th
50. ange is not used 2016 Reserved 2017 OFF BUTTON Note 1 2018 note 1 PID SLEEP This alarm warns that the PID sleep function is active which means that the motor could accelerate when the PID sleep function ends e To control PID sleep use parameters 4022 4026 or 4122 4126 ACH550 UH ACH550 Installation Operation and Maintenance Manual 31 Alarm Code Display Description 2019 ID RUN Performing ID run 2020 OVERRIDE This alarm warns that the Override function is active which may start the motor 2021 START ENABLE 1 MISSING This alarm warns that the Start Enable 1 signal is missing e To control Start Enable 1 function use parameter 1608 To correct check e Digital input configuration e Communication settings 2022 START ENABLE 2 MISSING This alarm warns that the Start Enable 2 signal is missing e To control Start Enable 2 function use parameter 1609 To correct check e Digital input configuration e Communication settings 2023 EMERGENCY STOP Emergency stop activated 2024 ENCODER ERROR The drive is not detecting a valid encoder signal Check for and correct e Encoder presence and proper connection reverse wired loose connection or short circuit e Voltage logic levels are outside of the specified range e A working and properly connected Pulse Encoder Interface Module OTAC 01 e Wron
51. anged Parameter mode Displays changed parameters Bypass Fault Display mode If there is an active bypass fault the control panel will flash the fault number and fault diagnostic indication in English Bypass Alarm Display mode If there is an active bypass alarm the control panel will flash the alarm number and alarm diagnostic indication in English Start up by changing the parameters from the start up list To change the parameters follow these steps 1 The Default Display indicates the Bypass Control mode 2 Press ENTER to enter the Main Menu ENTER ACH550 E Clipse Bypass 64 ACH550 Installation Operation and Maintenance Manual Select the Startup Params with the Up Down arrows and press ENTER V A ENTER Select the appropriate Parameter with the Up Down arrows and press ENTER V A ENTER Press the Up Down arrows to change the Parameter Value VA Press ENTER to store the modified value or press ESC to leave the Parameter Edit mode ENTER or ESC Press ESC to return to the Main Menu and again to return to the Default Display ESC To change the parameters follow these steps Start up by changing the parameters individually from the parameter list The Default Display indicates the Bypass Control mode Press ENTER to enter the Main Menu ENTER Select the Parameter List with the Up Down arrows and press EN
52. at provides the proper configuration settings by default is the E Clipse HVAC Default macro 9902 15 If any other ACH550 drive macro or any modified setting of the E Clipse HVAC Default macro is used the following ACH550 Drive parameter values must be set and power cycled or the E Clipse Bypass will not function properly e Parameter 9802 must be set to STD MODBUS e Parameter 1001 must be set to Comm e Parameter 1002 must be set to Comm e Parameter 1601 must be set to Comm e Parameter 1608 must be set to Comm e Parameter 5303 must be set to 76 8 kb s e Parameter 5304 must be set to 8 EVEN 1 e Parameter 5305 must be set to DCU PROFILE e Parameter 5310 must be set to 103 e Parameter 5311 must be set to 104 e Power must be cycled Refer to the ACH550 UH User s Manual for programming instructions Note Run motor from drive before attempting bypass operation System check motor disconnected from the ACH550 with E Clipse Bypass If you are familiar with the E Clipse Bypass operation you may skip the following section Otherwise after performing the system checks and setting the ACH550 Drive Start up Data parameters become familiar with the operation of the ACH550 Drive with E Clipse Bypass without the motor connected as follows 1 Disconnect and lock out power to the E Clipse Bypass unit wait at least five minutes after disconnecting power 2 Disconnect the mo
53. at the same potential ACH550 UH ACH550 Installation Operation and Maintenance Manual 17 Note For safety reasons the fault relay signals a fault when the ACH550 is powered down X1 Drive Control Terminal Description 1 SCR Terminal for signal cable screen Connected internally to chassis ground 2 All Analog input channel 1 programmable Default external reference Resolution 0 1 accuracy 1 J1 Al1 OFF 0 2 10 V Ri 312 kQ 2 gt mas ON or for OFF for ON i i J1 Al1 ON 0 4 20 mA Rj 100 Q o gt aie oes AGND Analog input circuit common connected internally to chassis gnd through 1 MQ 4 10V_ Potentiometer reference source 10 V 2 max 10 MA 1kQ lt R lt 10kQ Q Al2 Analog input channel 2 programmable Default PID feedback Resolution 0 1 ey accuracy 1 g J1 Al2 OFF 0 2 10 V R 312 KQ T2 P N ON lt or for OFF for ON J1 Al2 ON 0 4 20 mA R 100 Q o gt Gao aloe 6 AGND Analog input circuit common connected internally to chassis gnd through 1 MQ 7 AO1 Analog output programmable Default frequency 0 20 mA load lt 500 Q 8 AQ2 Analog output programmable Default cu
54. cement on page 33 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room 4 Replace the cooling fan Restore power ACH550 UH ACH550 Installation Operation and Maintenance Manual 33 Drive module fan replacement The drive module fan cools the heatsink Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts To monitor the running time of the cooling fan see Group 29 MAINTENANCE TRIG instructions Frame Sizes R1 R4 3 For Frame Size 4 5 6 Remove power from drive To replace the fan Remove drive cover e R1 R2 Press together the retaining clips on the fan cover sides and lift e R3 R4 Press in on the lever located on the left side of the fan mount and rotate the fan up and out Disconnect the fan cable Install the fan in reverse order Restore power Frame Sizes R5 and R6 3 Remove the fan 5 Install the fan in reverse order Remove power from drive To replace the fan
55. cessive emission propagated to neighboring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt use a supply transformer with static screening between the primary and secondary windings e Do NOT install an external RFI EMC filter Using an RFI filter grounds the input power through the filter capacitors which could be dangerous and could damage the unit Checking motor and motor cable insulation A WARNING Check the motor and motor cable insulation before connecting the drive to input power For this test make sure that motor cables are NOT connected to the drive Complete motor cable connections to the motor but NOT to the drive output terminals U2 V2 W2 At the drive end of the motor cable measure the insulation resistance between each motor cable phase and Protective Earth PE Apply a voltage of 1 kV DC and verify that D resistance is greater than 1 Mohm oe ACH550 UH ACH550 Installation Operation and Maintenance Manual 13 R1 R6 wiring UL type 1 enclosure 1 Install thin wall conduit clamps not supplied Open the appropriate knockouts in the conduit box See Conduit kit on page 7 3 Install conduit box 4 Connect conduit runs for input power motor 6 Strip wires 7 Connect power motor and ground wires to 10 11 12 13 14 Route input power and motor wiring through Route the control
56. clock function available and enabled The battery keeps the clock operating in memory during power interruptions The expected life for the battery is greater than ten years To remove the battery use a coin to rotate the battery holder on the back of the control panel Replace the battery with type CR2032 Note The battery is NOT required for any control panel or drive function except the clock ACH550 UH ACH550 Installation Operation and Maintenance Manual 39 ACH550 E Clipse Bypass Installation drive Follow the nstallation instructions for the drive on page 3 Failure to observe the warnings and instructions may cause a malfunction or personal hazard WARNING Before you begin read Safety on page 2 Installation bypass WARNING When the ACH550 with E Clipse Bypass is connected to the line power the Motor Terminals T1 T2 and T3 are live even if the motor is not running Do not make any connections when the ACH550 with E Clipse Bypass is connected to the line Disconnect and lock out power to the drive before servicing the drive Failure to disconnect power may cause serious injury or death 1 Install wiring bypass WARNING e Do not connect or disconnect input or output power wiring or control wires when power is applied e Never connect line voltage to drive output Terminals T1 T2 and T3 e Do not make any voltage tolerance tests Hi Pot or Megger on any part of the
57. d result in death or serious injury Install the control wiring Connect control wiring to terminal block X1 on the ACH550 control board and to terminal block X2 on the E Clipse Bypass control board For more information on these connections refer to the following e X1 terminal block location and terminal data are defined in the ACH550 UH User s Manual e X2 terminal block location is illustrated in the figures starting with Connection diagrams Vertical E Clipse Bypass on page 40 e X2 terminal data are provided in Basic control connections for E Clipse HVAC Default on page 52 e Basic connections are described in the following paragraphs Alternate configurations using the E Clipse Bypass macro are described in the ACH550 User s Manual e On Terminal Block X1 inside the ACH550 analog inputs and outputs and additional digital input and relay output connections Al1 Al2 AO1 AO2 DI1 DI6 and RO1 RO6 are available for use Note The E Clipse Bypass control circuitry uses serial communications connections X1 28 X1 32 inside the ACH550 These connections are not available for any other purpose and must not be reconfigured ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual Digital I O control terminals Drive s power connection terminals
58. e Control is 0103 and 0104 for active digital input status 4020 OVERRIDE 2 Alarm is generated NA Check Parameter when Fireman s 0103 and 0104 for Override is active digital input status 4021 Selected by PAR Alarm will occur when Run Enable conditionis Check 24 Volts on 1621 start order is given and not satisfied RBCU unit START ENABLE 1 the RUN Enable is not Bad 24v supply Check for 24 volts on VIBRATION present Bad digital input respective DI when SWITCH condition is satisfied 24 V common is not FIRESTAT tied to Digital input Check Parameter 0103 FREEZESTAT common on bypass For status of digital OVERPRESSURE when using external 24 Nput VIBRATION TRIP v supply SMOKE ALARM SAFETY OPEN LOW SUCTION PRES ACH550 E Clipse Bypass 74 ACH550 Installation Operation and Maintenance Manual path AR TE i Alarm Possible Cause Corrective Action 4022 Selected by PAR Alarm will occur when Run Enable condition is Check 24 Volts on 1622 start order is given and not satisfied RBCU unit START ENABLE 2 the irk Enable is not Bad 24v supply Check for 24 volts on VIBRATION presen Bad digital input terrea DI wen SWITCH 24 V common is not condition is satisfie i tied to Digital input Check Parameter 0103 LOW SUCTION common on bypass For status of digital PRES when using external 24 Input v supply 4023 Selected by PAR Alarm will occur when Run Enable condition is Check 24
59. e Power Replace RBCU 3204 STACK Program cycle is NA Contact ABB with OVERFLOW overloaded information that proceeded fault Cycle Power Replace RBCU ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 71 Fault Code Fault Name In Panel Fault Possible Cause Corrective Action 3205 UNKNOWN CB Bypass control board type is unknown Firmware is not compatible with control board in RBCU Firmware 93F and greater compatible with all RCBU hardware Firmware 93D and earlier can only be loaded in RBCU Rev D and earlier 3206 UNKNOWN DRIVE Drive reports rating not found in bypass software Drive does not match drives configured in bypass RBCU Replace RBCU or reload with most current firmware 3207 UNKNOWN BYPASS NA NA Replace RBCU or load most current firmware Contact ABB at 1 800 HELP 365 option 4 Replace RBCU or load most current firmware Fault History See page 28 Alarm listing The following table lists the alarms by code number and describes each Alarm Alarm Name In 7 i i Code Panel Alarm Possible Cause Corrective Action 4001 INP PHASE A Alarm will occur in drive Loose J8 connector Check J8 connector LOSS mode In bypass Loose wiring on Check yellow wire on alarm will occur if Contactor assembly input block bypass contactor has BI t f Check i not closed Unit will tr
60. e contactor armature moves or after contact is freely If armature commanded to open moves freely then change the RBCU If armature does not move freely then change individual contactor M2 or the complete assembly RCSA Ox 3003 DRV CNTACT M1 contactor indicates Defective Contactor Disconnect incoming STUCK it is not prepared to Defective RBCU power from unit MOVE On a ROWET ae Check if contactor check of the contactor armature moves or after contact is freely If armature commanded to open moves freely then change the RBCU If armature does not move freely then change individual contactor M1 or the complete assembly RCSA Ox ACH550 E Clipse Bypass 66 ACH550 Installation Operation and Maintenance Manual Fault Fault Name In 5 Code Panel Fault Possible Cause Corrective Action 3004 BYPASS COIL M2 contactor will not Loose J8 connector Verify that J8 OPEN close when on RBCU connector is firmly commanded to do so Loose wires on seated contactor terminals A1 With incoming power and or A2 disconnected check Bad Output on RBCU for tightness of A1 and A2 terminals Bad Contactor Swap RBCU Change Contactor Assembly 3005 DRIVE COIL M1 contactor will not Loose J8 connector Verify that J8 OPEN close when on RBCU connector is firmly commanded to do so Loose wires on seated contactor terminals A1 With incoming power and or A2 disconnected check Bad Output
61. e filter frame will slide up approximately 3 4 inch and can then safely removed by tilting away from the cabinet and lifting up ACH550 UH 36 2 Lay the filter frame on a flat work Reinstall the 3 filter restraining ACH550 Installation Operation and Maintenance Manual surface Remove the 3 retaining brackets by squeezing the tabbed corners in towards the middle of each bracket until the bracket clears the filter frame Save these brackets for replacement Remove and inspect the filter C B A Chia A a PC00009 PC00007 Install the replacement filter Be g sure to tuck the filter into the grove around the entire filter frame This is very important for proper installation PC00013 brackets These will prevent the filter from being pulled out of the filter frame e Install the center bracket first e Install the 2nd bracket overlapping the center bracket by 1 2 to the left e Install the 3nd bracket overlapping the center bracket by 1 2 to the right CLL 1st filter retaining bracket st and 2nd filter retaining brackets All 3 filter retaining brackets PC00007 Install the filter frame back to the cabinet door Carefully align the mounting hooks to the slots in the cabinet door The hooks should be pointing down Press in at the center of the filter frame with your knee and gently press down with your hands at the top of the frame The filter frame will slide down approximately 3 4 i
62. e the cabinet into position over the existing warning on the top of the module R8 Note If the cabinet location does not provide access to the cabinet sides be sure to re mount side panels before positioning cabinet Install and tighten mounting bolts 5 Install wiring WARNING Ensure the motor is compatible for use with the ACH550 The ACH550 must be installed by a competent person If in doubt contact your local ABB sales or service office Conduit kit Wiring R1 R6 drives with the UL type 1 Enclosure requires a conduit kit with the following items e conduit box e screws e cover The kit is included with UL type 1 Enclosures ACH550 UH 8 ACH550 Installation Operation and Maintenance Manual Connection diagrams The following diagrams show e The terminal layout for frame size R3 which in general applies to frame sizes R1 R6 except for the R5 R6 power and ground terminals e The R5 R6 power and ground terminals e The terminal layout for R7 R8 R1 R4 Diagram shows the R3 frame J1 DIP Switches for Analog Inputs The switchi isrone ot two ypes Illustration of available switch positions not default settings o gt Alt in Voltage Position Q P Al2 in Current Position Original Alternate Panel Connector X1 Analog Inputs and Outputs and 10 V Ref Voltage Output Power LED Green Fault LED Red X1 Digital Inputs and 2
63. either the drive s estimate or on temperature feedback e Check for overloaded motor e Adjust the parameters used for the estimate 3005 3009 e Check the temperature sensors and Group 35 parameters 10 PANEL LOSS Panel communication is lost and either e Drive is in local control mode the control panel displays HAND or OFF or e Drive is in remote control mode AUTO and is parameterized to accept start stop direction or reference from the control panel To correct check e Communication lines and connections e Parameter 3002 PANEL COMM ERROR e Parameters in Group 10 START STOP DIR and Group 11 REFERENCE SELECT if drive operation is AUTO 11 ID RUN FAIL The motor ID run was not completed successfully Check for and correct e Motor connections e Motor parameters 9905 9909 do not match motor nameplate 12 MOTOR STALL Motor or process stall Motor is operating in the stall region Check for and correct e Excessive load e Insufficient motor power e Parameters 3010 3012 14 EXTERNAL FLT 1 Digital input defined to report first external fault is active See parameter 3003 EXTERNAL FAULT 1 15 EXTERNAL FLT 2 Digital input defined to report second external fault is active See parameter 3004 EXTERNAL FAULT 2 16 EARTH FAULT Possible ground fault detected in the motor or motor cables The drive monitors for ground faults while the drive is running and while t
64. ended by ABB Maintenance Application Interval Instruction Check replace R7 R8 R7 R8 UL type 12 Check every 3 Frame Sizes R7 R8 UL enclosure inlet air filter enclosures months Replace as type 12 enclosure inlet air needed filter on page 35 Check replace R7 R8 R7 R8 UL type 12 Check every 6 Frame Sizes R7 R8 UL enclosure exhaust air enclosures months Replace as type 12 enclosure exhaust filter needed filters on page 37 Check and clean All Depends on the See Heatsink below heatsink dustiness of the environment every 6 12 months Replace drive module All Every six years See Drive module fan fan replacement on page 33 Replace enclosure fan UL type 12 Every three years See Enclosure fan enclosures replacement UL Type 12 enclosures on page 34 Change capacitor Frame sizes R5 R6 and R8 Every ten years See Capacitors on page 38 Replace battery in the Assistant control panel All Every ten years See Control panel on page 38 Heatsink The heatsink fins accumulate dust from the cooling air Since a dusty heatsink is less efficient at cooling the drive overtemperature faults become more likely In a normal environment not dusty not clean check the heatsink annually in a dusty environment check more often Clean the heatsink as follows when necessary 1 Remove power from drive Remove the cooling fan see section Drive module fan repla
65. es Ground Lug ACH550 Bar Motor Terminals i pps Input Power Terminals Disconnect Switch or Circuit Breaker Dashed line is ground run Note The terminals on disconnect switches for the following rated ACH550 PDR products is 7 in lobs Do not use a power driver or over tighten to prevent breaking screw heads or stripping the terminal 230 VAC 460 VAC 600 VAC 04A6 2 03A3 4 02A7 6 O6A6 2 04A1 4 03A9 6 07A5 2 06A9 4 06A1 6 012A 2 08A8 4 09A0 6 017A 2 012A 4 O11A 6 024A 2 015A 4 017A 6 031A 2 023A 4 ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 81 Power connection terminals The following tables show maximum wire size and required tightening torque for incoming power grounding and motor terminals 208 240 Volt Power Wiring Data Base Circuit Circuit Disconnect Disconnect Ground Ground Drive Breaker Breaker Switch Switch Lugs Lugs 1 Frame Motor g HP Type Code UL Type UL Type UL Type UL Type terminals UL Type UL Type Size NEMA NEMA NEMA NEMA NEMA NEMA 1 amp 12 3R 1 amp 12 3R 1 amp 12 3R 1 ACH550 PxR 04A6 2 R1 1 5 ACH550 PxR 06A6 2 R1 10 10 10 10 10 10 22 ACHS30 FXR 07AS72 R1 35 in lbs 35 in lbs 7 in lbs 7 in lbs 35 in lbs 35 in lbs 3 ACH550 PxR 012A 2 R1 5 ACH550 PxR 017A 2 R1 7 5 ACH550 PxR 024A
66. es on enclosures page 87 Check replace floor Floor mount UL Check every 3 See Maintenance on page 34 and mount enclosure inlet Type NEMA 12 months Replace Enclosure air filter replacement air filter enclosures as needed UL Type NEMA 12 hinged door wall mount enclosures on page 87 Check replace NEMA UL Type NEMA Check every 3 See PX3R dimensional 3R enclosure air filters 3R enclosures months Replace information PX3R 5 and as needed higher Check replace floor Floor mount UL Check every 6 See Maintenance on page 35 and mount enclosure Type NEMA 12 months Replace Enclosure air filter replacement exhaust air filter enclosures as needed UL Type NEMA 12 hinged door wall mount enclosures on page 87 Enclosure air filter replacement UL Type NEMA 12 hinged door wall mount enclosures Filter material Material Filter Type American Air Filter 358 35 06A 12A Polykleon White 12 7 mm x 152 4 mm x 304 6 mm stk This procedure applies to drive with input disconnect configurations in UL Type NEMA 12 hinged door wall mount enclosures This filter is located at the bottom of the enclosure Use the following procedure to check and replace filters On the enclosure remove the screw holding the filter bracket in place Slide the filter bracket forward until the hooks on the bracket clear the slots on the enclosure base This step allows the filter and bracket to drop free from the
67. g value entered in parameter 5001 PULSE NR A wrong value will only be detected if the error is such that the calculated slip is greater than 4 times the rated slip of the motor e Encoder is not being used but parameter 5002 ENCODER ENABLE 1 ENABLED 2025 FIRST START Signals that a the drive is performing a First Start evaluation of motor characteristics This is normal the first time the motor is run after motor parameters are entered or changed See parameter 9910 MOTOR ID RUN for a description of motor models 2026 RESERVED Not used 2027 USER LOAD CURVE This alarm warns that the condition defined by parameter 3701 USER LOAD C MODE has been valid longer that half of the time difined by 3703 USER LOAD C TIME 2028 START DELAY Shown during the Start delay See parameter 2113 START DELAY Note 1 Even when the relay output is configured to indicate alarm conditions e g parameter 1401 RELAY OUTPUT 1 5 ALARM or 16 FLT ALARM this alarm is not indicated by a relay output Maintenance Warning Read Safety on page 2 before performing any maintenance on the equipment Ignoring the safety instructions can cause injury or death ACH550 UH 32 Maintenance intervals ACH550 Installation Operation and Maintenance Manual If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recomm
68. h 1 Install wiring WARNING e Metal shavings or debris in the enclosure can damage electrical equipment and create a hazardous condition Where parts such as conduit plates require cutting or drilling first remove the part If that is not practical cover nearby electrical components to protect them from all shavings or debris Do not connect or disconnect input or output power wiring or control wires when power is applied e Never connect line voltage to drive output Terminals T1 T2 and T3 e Do not make any voltage tolerance tests Hi Pot or Megger on any part of the unit Disconnect motor wires before taking any measurements in the motor or motor wires e Make sure that power factor correction capacitors are not connected between the drive and the motor ACH550 PCR PDR 78 ACH550 Installation Operation and Maintenance Manual Connection diagrams standard drive with input disconnect wall mounted The following figure shows the Standard Drive with Input Disconnect wall mounted wiring connection points UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 Vertical Construction ACH550 Hinged Door Wall Mount VO Conduit Enclosures Enclosures Top Ground Lug s Terminals Motor Disconnect Switch i roret Terminals or Circuit Breaker Input Power Terminals 1 0 Conduit Bottom UL Type NEMA 3R Enclosures Fan Space Heater Power Supply amp Control Assembly D
69. hange if reverse operation is safe 2005 I O COMM Fieldbus communication has timed out Check for and correct e Fault setup 3018 COMM FAULT FUNC and 3019 COMM FAULT TIME e Communication settings Group 51 or 53 as appropriate e Poor connections and or noise on line 2006 Al1 Loss Analog input 1 is lost or value is less than the minimum setting Check e Input source and connections e Parameter that sets the minimum 3021 e Parameter that sets the Alarm Fault operation 3001 2007 Al2 LOSS Analog input 2 is lost or value is less than the minimum setting Check e Input source and connections e Parameter that sets the minimum 3022 e Parameter that sets the Alarm Fault operation 3001 ACH550 UH 30 ACH550 Installation Operation and Maintenance Manual Alarm Code Display Description 2008 PANEL LOSS Panel communication is lost and either e Drive is in local control mode the control panel displays HAND or OFF or e Drive is in remote control mode AUTO and is parameterized to accept start stop direction or reference from the control panel To correct check e Communication lines and connections e Parameter 3002 PANEL LOSS e Parameters in Groups 10 START STOP DIR and 11 REFERENCE SELECT if drive operation is AUTO 2009 DEVICE OVERTEMP Drive heatsink is hot This alarm warns that a DEVICE OVERTEMP fault may be near R1 R4 amp R7 R8 100 C 212 F R5 R6 110 C
70. hannel e Squeeze the open end of the U until it clears the filter frame e Seatthe open end of the U Pcooors PC0000 in the filter frame channel e Release the retainer to its relaxed square shape ACH550 UH 38 Install each filter frame to the bonnet on top ACH550 Installation Operation and Maintenance Manual of the cabinet e Carefully align the frame s mounting hooks with the slots in the bonnet The hooks should be pointing down e Press down at the top of the filter frame The filter frame slides down approximately 3 4 inch t n PC00012 PC00011 e Check all around the filter frame for a secure seal to the exhaust box Capacitors The drive intermediate circuit employs several electrolytic capacitors Their life span is from 35 000 90 000 hours depending on drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failure Capacitor failure is usually followed by a input power fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements for frame size R5 R6 and R8 are available from ABB Do not use other than ABB specified spare parts Control panel Cleaning Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Battery A battery is only used in Assistant control panels that have the
71. he drive is not running Detection is more sensitive when the drive is not running and can produce false positives Possible corrections e Check for correct faults in the input wiring e Verify that motor cable does not exceed maximum specified length e A delta grounded input power supply and motor cables with high capacitance may result in erroneous error reports during non running tests To disable response to fault monitoring when the drive is not running use parameter 3023 WIRING FAULT To disable response to all ground fault monitoring use parameter 3017 EARTH FAULT 17 UNDERLOAD Motor load is lower than expected Check for and correct e Disconnected load e Group 37 USER LOAD CURVE 18 THERM FAIL Internal fault The thermistor measuring the internal temperature of the drive is open or shorted Contact your local ABB sales representative 19 OPEX LINK Internal fault A communication related problem has been detected on the fiber optic link between the OITF and OINT boards Contact your local ABB sales representative 20 OPEX PWR Internal fault Low voltage condition detected on OINT power supply Contact your local ABB sales representative ACH550 UH 26 ACH550 Installation Operation and Maintenance Manual Fault Code Fault Name In Panel Description and Recommended Corrective Action 21 CURR MEAS Internal fault Current measurement is out of range
72. he input power is a delta grounded system and motor cable capacitance is large This fault can be disabled using parameter 3023 WIRING FAULT 36 INCOMP The drive cannot use the software SWTYPE e Internal Fault e The loaded software is not compatible with the drive e Call support representative 37 CB OVERTEMP Drive control board is overheated Check for and correct e Excessive ambient temperatures e Fan failure e Obstructions in the air flow 101 SERF CORRUPT Error internal to the drive Contact your local ABB sales representative and report the error number 102 RESERVED 103 SERF MACRO 104 RESERVED 105 RESERVED 201 DSP T1 Error in the system Contact your local ABB sales representative and report OVERLOAD the error number 202 DSP T2 OVERLOAD 203 DSP T3 OVERLOAD 204 DSP STACK ERROR 205 RESERVED obsolete 206 OMIO ID ERROR 207 EFB LOAD ERR 1000 PAR HZRPM Parameter values are inconsistent Check for any of the following LIMITS e 2001 MINIMUM SPEED gt 2002 MAXIMUM SPEED e 2007 MINIMUM FREQ gt 2008 MAXIMUM FREQ e 2001 MINIMUM SPEED 9908 MOTOR NOM SPEED is outside proper range gt 50 e 2002 MAXIMUM SPEED 9908 MOTOR NOM SPEED is outside proper range gt 50 e 2007 MINIMUM FREQ 9907 MOTOR NOM FREQ is outside proper range gt 50 e 2008 MAXIMUM FREQ 9907 MOTOR NOM FREQ is outside proper range gt 50 1001 PAR PFAREFNG Parameter values are inconsistent Check for the following e 2007 MINIMU
73. ing and diagnosing the drive To reach the Standard Display Mode press EXIT until the LCD display shows status information Select MENU and use UP DOWN buttons to select other modes The modes are Standard Display Mode Shows drive status information and operates the drive Parameters Mode Edits parameter values individually Start up Assistant Mode Guides the start up and configuration Changed Parameters Mode Shows changed parameters Fault Logger Mode Shows the drive fault history Drive Parameter Backup Mode Stores or uploads the parameters Clock Set Mode Sets the time and date for the drive I O Settings Mode Checks and edits the I O settings Alarm Mode Reporting mode triggered by drive alarms ACH550 UH 22 ACH550 Installation Operation and Maintenance Manual Operating the drive AUTO HAND The very first time the drive is powered up it is in the auto control AUTO mode and is controlled from the Control terminal block X1 To switch to hand control HAND and control the drive using the control panel press and hold the gt or p button e Pressing the HAND button switches the drive to hand control while keeping the drive running e Pressing the OFF button switches to hand control and stops the drive To switch back to auto control AUTO press and hold the button Hand Auto Off To start the drive press the HAND or AUTO buttons to stop the drive press the OFF butto
74. ip OWN upstream tuse pam on Fault 3010 if the vo T pnaseto bypass contactor is groun closed 4002 INP PHASE B Alarm will occur in drive Loose J8 connector Check J8 connector LOSS mode In bypass Loose wiring on Check black wire on alarm will occur if Contactor assembly input block bypass contactor has BI t f Check i not closed Unit will trip OWN upstream tuse ee on Fault 3011 if the vO oa phase to bypass contactor is groun closed 4003 INP PHASE C Alarm will occur in drive Loose J8 connector Check J8 connector LOSS mode In bypass Loose wiring on Check red wire on input alarm will occur if Contactor assembly block bypass contactor has BI t f Check i not closed Unit will trip OWN upstream tuse eee on Fault 3012 if the vo aa prase to bypass contactor is groun closed ACH550 E Clipse Bypass 72 ACH550 Installation Operation and Maintenance Manual messages has exceeded timeout interval set with parameter 3005 Communication settings in Group 51 amp 53 Poor Connections Noise on Communication Line Alarm Alarm Name In Alarm Possible Cause Corrective Action Code Panel 4004 AUTO TRANSFER Message is displayed Drive fault Check drive when the drive faults and the bypass switches to bypass mode as configured in Parameter 1608 4005 EXT COMM ERR Time between fieldbus Incorrect Check Group 51 amp 53 Tighten Connections Check Communication Cable Grounding
75. ipse Bypass standard ACH550 Drive ACH CP B Control Panel E Clipse Bypass BP0091 configurations and identifies the major components ACH550 Drive with E Clipse Bypass ACH CP B Control Panel E Clipse Bypass Control Panel Operating Handle for Disconnect Switch or Circuit Breaker E Clipse Bypass Control Panel Operating Handle for Disconnect Switch or Circuit Breaker i ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 61 The following is a typical power diagram Disconnect Switch Drive with E Clipse Bypass fan Bypass Drive Output or Circuit Breaker i gal Contactor 3 Phase Input Power 3 Service Switch Optional L l Bypass Contactor Drive Input Fuse Bypass control The bypass control panel features Ready Indication Display Illuminated n LCD Display Display Down Up ee Se mwao EE A A Be Drive and Bypass Selected Faulted LEDs ON Hand Key SELECTED FAULTED OFF Reset Key Drive Bypass Select Keys RON Motor Run LED Ready Power On Indication The Ready Power On indication is provided by the bypass control panel The bypass control panel display will be illuminated and text will be displayed when the
76. isconnect Switch or Circuit Breaker ACH550 Input Power Motor Terminals Terminals 1 0 Conduit Ground Bottom Lug Note Type 3R enclosures are designed to be mounted on a wall For 3R enclosure back plates which maintain 3R integrity when the enclosure is mounted on an open rack system contact your ABB HVAC Drives Distributor ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 79 Connection diagrams standard drive with input disconnect floor mounted Floor mounted UL Type NEMA 1 amp 12 Drive with Input Disconnect units are configured for wiring access from the top and include a removable conduit mounting plate The following figure shows the wiring connection points Ground Lug ACH550 Bar Motor Terminals ES Input Power Terminals Disconnect Switch or Circuit Breaker ACH550 PCR PDR 80 ACH550 Installation Operation and Maintenance Manual Line input connections standard drive with input disconnect configurations Connect input power to the terminals of the disconnect switch or circuit breaker Connect the equipment grounding conductor to the ground lug at the top of the enclosure The figure below shows the connection points for Standard Drive with Input Disconnect configurations UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 Vertical Construction _ Hinged Door Wall Mount Input Floor Mount Enclosures 1 Enclosures Power Enclosur
77. itional cooling Posie RRI too high Replace RBCU Bad RBCU unit ACH550 E Clipse Bypass 70 ACH550 Installation Operation and Maintenance Manual Fault Fault Name In F Code Panel Fault Possible Cause Corrective Action 3038 NO DRIVE DATA No drive data Bypass not able to Proper seating of available Group 112 extract drive data on cable in drive and initial power up due to RBCU connector J3 Bad cable connection Check drive between drive and parameter 9802 bypass Modbus and 9902 Communication E Clipse improperly set in drive Check drive Group 53 Parameter 9802 Follow DriveLink Application Macro recovery procedure improperly set in drive then cycle power to parameter 9902 bypass 3039 FBA PAR CONF Non embedded Incorrect settings in Verify Group 51 fieldbus has detected Group 51 parameters an error in Group 51 parameters 3101 SFLASH Internal checksum NA Cycle power CORRUPT error Replace RBCU Upgrade firmware 3102 PMAP FILE Parameter file is Cycle Power corrupt Contact ABB with information that preceeded fault 3201 T1 OVERLOAD T1 program cycle is NA Contact ABB with overloaded information that proceeded fault Cycle Power Replace RBCU 3202 T2 OVERLOAD T2 program cycle is NA Contact ABB with overloaded information that proceeded fault Cycle Power Replace RBCU 3203 T3 OVERLOAD T3 program cycle is NA Contact ABB with overloaded information that proceeded fault Cycl
78. l power 2 Edit parameters 9905 9909 to the correct values e Assistant Control Panel The Start Up Assistant walks you through this data entry e Basic Control Panel Refer to ACH550 User s Manual for parameter editing instructions Fault and alarm adjustments The ACH550 can detect a wide variety of potential system problems For example initial system operation may generate faults or alarms that indicate set up problems 1 Faults and alarms are reported on the control panel with a number Note the number reported 2 Review the description provided for the reported fault alarm e Use the fault and alarm listings on pages 24 and 29 respectively or e Press the help key Assistant Control Panel only while fault or alarm is displayed 3 Adjust the system or parameters as appropriate ACH550 UH ACH550 Installation Operation and Maintenance Manual 21 Operation The ACH550 HVAC control panel ACS CP B features Status LED Green when normal if flashing or red see Diagnostics UP SOFT KEY 1 DOWN p OAY O O PDN AUTO HELP always available HP ee X0201 General display features Soft key functions The soft key functions are defined by text displayed just above each key Display contrast To adjust display contrast simultaneously press GS and lt 4 or vw as appropriate HVAC control panel modes The HVAC control panel has several different modes for configuring operat
79. lace RBCU unit 3016 EARTH FAULT Declared if attempting Earth fault in motor Refer to the fault code to close the bypass 16 on page 25 contactor when the drive has earth fault declared ACH550 E Clipse Bypass 68 ACH550 Installation Operation and Maintenance Manual Fault Fault Name In 5 Code Panel Fault Possible Cause Corrective Action 3017 MTR If motor power Broken belt Check load UNDERLOAD level falls below Reset bypass keypad minimum power level establish in parameter Check a Paki be 3003 for the time s ear cee MOTIUTIET set in parameter 3002 acuon fault will be generated Parameter 3003 is a percentage of motor power as defined in the drive via parameter 9909 Fault only applies to bypass mode 3018 MAX CYCLE Supervisory Mode High and low levels of Check parameters FAULT only Declared if hysteresis band are 3202 3205 Increase bypass contactor is too tight time delays on closed by supervisory parameters 3204 and control 16 times within 3205 a 1 hour period 3019 DRIVE LINK Supervisory Mode Bad cable connection Proper seating of FAULT Only Fault generated between drive and cable in drive and if RS 485 link between bypass RBCU connector J3 drive and bypass Communication Check drive stops communicating improperly set in drive parameter 9802 Parameter 9802 Modbus and 9902 Application Macro E Clipse improperly set 1 drive Check drive Group 53 parameter
80. lipse Bypass on page 43 Connect the motor grounding conductor to the ground lug near the motor cable terminal block connection point Power connections Standard E Clipse Bypass configurations wall mounted Line input connections Connect input power to the terminals of the disconnect switch or circuit breaker Connect the equipment grounding conductor to the ground lug at the top of the enclosure The figure below shows the connection points for Standard E Clipse Bypass configurations Also see Connection diagrams Standard E Clipse Bypass wall mounted on page 47 and Connection diagrams Standard E Clipse Bypass R8 floor mounted on page 43 Motor connections Connect the motor cables to the output terminal block as shown in the figure below Also see Connection diagrams Standard E Clipse Bypass wall mounted on page 41 and Connection diagrams Standard E Clipse Bypass R8 floor mounted on page 43 The motor grounding conductor can be connected to the ground lug near the terminal block Note Route cables through the cable guides on the left side of the enclosure Use separate conduits for input power and motor cables Follow the guides to separate the cables from each other ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 45
81. ltage from external sources on the terminals of the relay outputs e WARNING When the control terminals of two or more drives are connected in parallel the auxiliary voltage for these control connections must be taken from a single source which can either be one of the drives or an external supply e WARNING Disconnect the internal EMC filter when installing the drive on an IT system an ungrounded power system or a high resistance grounded over 30 ohm power system e WARNING Do not attempt to install or remove EM1 EMBs F1 or F2 screws while power is applied to the drive s input terminals General warning warns about AN conditions other than those caused by electricity which can result in physical injury and or damage to the equipment e WARNING Do not control the motor with the disconnecting device disconnecting means instead use the control panel keys or commands via the I O board of the drive The maximum allowed number of charging cycles of the DC capacitors i e power ups by applying power is five in ten minutes e WARNING Never attempt to repair a malfunctioning ACH550 contact the factory or your local Authorized Service Center for repair or replacement e WARNING The ACH550 will start up automatically after an input voltage interruption if the external run command is on e WARNING The heat sink may reach a high temperature Note For more technical information contact the facto
82. n Reference To modify the reference only possible if the display in the upper right corner is in reverse video press the UP or DOWN buttons the reference changes immediately The reference can be modified in the local control mode HAND OFF and can be parameterized using Group 11 reference select to also allow modification in the remote control mode Note The Start Stop Shaft direction and Reference functions are only valid in local control HAND OFF mode Start up by using the Start Up Assistant To start the Start Up Assistant follow these steps Select MENU to enter the main menu u 1 Select ASSISTANTS with the Up Down buttons and select ENTER A 2 y u Scroll to COMMISSION DRIVE with the Up Down buttons CA Change the values suggested by the assistant to your preferences and then u 4 press SAVE after every change The Start Up Assistant will guide you through the start up ACH550 UH ACH550 Installation Operation and Maintenance Manual 23 Start up by changing the parameters individually To change the parameters follow these steps Select MENU to enter the main menu z Select the Parameters mode with the UP DOWN buttons and select ENTER to select the Parameters mode 2 Select the appropriate parameter group with the UP DOWN buttons and select 3 SEL Select the appropriate parameter in a group with the UP DOWN buttons Select
83. nch and should be sealed securely to the door around the entire filter frame ACH550 UH ACH550 Installation Operation and Maintenance Manual 37 Frame Sizes R7 R8 UL type 12 enclosure exhaust filters The exhaust filters in the R7 R8 UL type 12 enclosure are located in the exhaust box at the top of the enclosure There are 2 filter frames attached to the exhaust box 1 Remove each filter frame e Lift up on the filter frame until it slides approximately 3 4 inch HNN ANI e Pull away from the exhaust box to remove PC00021 2 For each filter frame remove the wire retainers that hold the filters in place e Lay the filter frames on a flat work surface e The wire retainers have a square U shape Remove by squeezing the open end of the U towards the middle of the square until the retainer top open end of U clears the filter frame PC00001 PC00019 e Save the retainers for reinstallation 3 Remove and inspect the filter 4 Install clean filters Note When installing DUSTLOK filter media the white side must face to outside of the cabinet and the orange side faces in Be sure to tuck the filter edges into the groove around the entire filter frame This detail is very important for proper operation PC00022 5 Reinstall the filter restrainers e Insert the base of a retainer bottom of U shape into a filter frame c
84. nding configuration of the network is unknown remove EM3 Note ACH550 UH drives are shipped with the screw removed but included in the conduit box Unsymmetrically Grounded Networks EM3 Must Be Out Grounded at the Grounded at the L1 l f L1 corner of the mid point of a delta delta leg le Y L2 L3 L3 Single phase L1 Three phase L1 grounded at an Variac without L1 end point solidly grounded neutral N L2 L3 ACH550 UH 12 ACH550 Installation Operation and Maintenance Manual EM3 an M4x16 screw makes an internal ground connection Li that reduces electro magnetic emission Where EMC electro magnetic compatibility is a concern and the network is symmetrically grounded EM3 may be installed For reference the diagram at right illustrates a symmetrically grounded network T Floating networks WARNING Do not attempt to install or remove EM1 EM3 F1 or F2 screws while power is applied to the drive s input terminals For floating networks also known as IT ungrounded or impedance resistance grounded networks e Disconnect the ground connection to the internal RFI filters Frame sizes R1 R4 Remove the EM1 screw unit is shipped with EM3 removed see Connection diagrams on page 8 Frame sizes R5 R6 Remove both the F1 and F2 screws see page 9 e Where EMC requirements exist check for ex
85. nfiguration file has an error Contact your local ABB sales representative 28 SERIAL 1 ERR Fieldbus communication has timed out Check for and correct e Fault setup 3018 COMM FAULT FUNC and 3019 COMM FAULT TIME e Communication settings Group 51 or 53 as appropriate e Poor connections and or noise on line 29 EFB CONFIG FILE Error in reading the configuration file for the embedded fieldbus 30 FORCE TRIP Fault trip forced by the fieldbus See the fieldbus User s Manual 31 EFB 1 32 EFB 2 33 EFB 3 Fault code reserved for the embedded fieldbus EFB protocol application These codes are not used as of the publication of this manual 34 MOTOR PHASE Fault in the motor circuit One of the motor phases is lost Check for and correct e Motor fault e Motor cable fault e Thermal relay fault if used e Internal fault ACH550 UH ACH550 Installation Operation and Maintenance Manual 27 Fault Fault Name In n g A Code Panel Description and Recommended Corrective Action 35 OUTPUT WIRING Possible power wiring error detected When the drive is not running it monitors for an improper connection between the drive input power and the drive output Check for and correct e Proper input wiring line voltageis NOT connected to drive output e The fault can be erroneously declared if t
86. ntrol panel display the output current indication should indicate 0 0 A Press the DOWN arrow on the drive control panel until the speed and frequency indications return to 0 0 Press the OFF key on the drive control panel Note that the bottom line of the drive contol panel display indicates Off ACH550 E Clipse Bypass 58 ACH550 Installation Operation and Maintenance Manual If the ACH550 Drive and E Clipse Bypass operate according to these steps and you have familiarized yourself with their operation disconnect and lock out power to prepare for the next test WARNING Wait at least five minutes after disconnecting power from the drive before you attempt to service the drive Bus capacitors in the intermediate DC circuit must discharge before servicing the drive Using a meter rated for 1000 VDC check for zero volts at e Terminals BRK to GND and BRK to GND frame size R1 R2 e Terminals UC and UC frame size R3 R8 If the drive does not operate according to these steps refer to the ACH550 UH User s Manual 3 Check jumpers and switches The settings described in this section are factory set and for most situations do not require adjustment However it is a good practice to review these settings to confirm that they are appropriate for the configuration installed Jumper and switch locations The figure below shows the locations of the SW1 DIP switch on the E Clipse Bypass control b
87. oard The function and setting of this switch is explained in the following paragraph Serial Communications Termination Resistors i Swi Factory TiS L lt ON Terminated installed O OFF Not Terminated jumpers 5 A is ig oS gt 8 O C Q Hooked wire j B race tie points Is 1 mma g i ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 59 DIP switch settings The DIP switch is used to configure the serial communications termination resistors To reduce noise on the serial communications network terminate the EIA 485 network using 120 ohm resistors at both ends of the network Use the DIP switches to connect or disconnect the on board termination resistors Both switches must be positioned in the ON or OFF position to correctly configure the termination resistors Note When using embedded protocols set SW1 in the OFF position Circuit breaker settings Operation On some ACH550 E Clipse Bypasses the circuit breaker has adjus
88. or many situations However review the following situations Perform the associated procedures as appropriate Spin motor When first installed and started the control panel displays a welcome screen with the following options e Press Exit to commission the drive as described in section Start up by changing the parameters individually on page 23 e Press Enter to move to the following options Select Commission Drive to commission the drive as described in section Start Up by Start up by using the Start Up Assistant on page 23 Select Spin Motor to operate the motor prior to commissioning This option ACH550 UH 20 ACH550 Installation Operation and Maintenance Manual operates the motor without any commissioning except entry of the motor data as described below Spin Motor is useful for example to operate ventilation fans prior to commissioning Note When using Spin Motor the motor speed is limited to the range 1 3 2 3 of maximum speed Also no interlocks are activated Finally once the drive is commissioned the welcome screen and this option no longer appear Motor data The motor data on the ratings plate may differ from the defaults in the ACH550 The drive provides more precise control and better thermal protection if you enter the rating plate data 1 Gather the following from the motor ratings plate e Voltage e Nominal motor current e Nominal frequency e Nominal speed e Nomina
89. ower source for the motor ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 63 Bypass Select Key The Bypass Select Key selects the bypass as the power source for the motor Off Reset Key The Off Reset Key may be used to manually stop the motor if the motor has been running on bypass power The Off Reset key also resets most bypass faults It may take several minutes before the bypass can be reset after an overload trip If a bypass fault condition is present the second press of this key places the bypass in the OFF mode Auto Key The Auto Key selects the Auto Start contact or serial communications as the means for starting and stopping the motor in the bypass mode Hand Key The Hand Key can be used to manually start the motor when the bypass has been selected as the power source for the motor Bypass control panel modes The HVAC Bypass Control Panel has several different modes for configuring operating and diagnosing the bypass Select MENU and use the UP DOWN buttons to select modes The modes are Default Display mode Provides HAND OFF AUTO indication of the bypass operating control mode Bypass Status mode Provides status indications of the current system operating conditions Start Up Parameter Mode Provides a list of parameters or operating conditions that may be configured or viewed during startup Parameter List mode Used to edit parameter values individually Ch
90. rameters 0402 0411 to aid in troubleshooting a problem For example parameter 0404 stores the motor speed at the time of the fault ACH550 UH ACH550 Installation Operation and Maintenance Manual 29 To clear the fault history all of the Group 04 Fault History parameters 1 Using the control panel in Parameters mode select parameter 0401 2 Press EDIT 3 Press UP and Down simultaneously 4 Press SAVE Alarm listing The following table lists the alarms by code number and describes each pas Display Description 2001 OVERCURRENT Current limiting controller is active Check for and correct e Excessive motor load e Insufficient acceleration time parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2 e Faulty motor motor cables or connections e Output disconnect device not interlocked e Interaction with external input filter 2002 OVERVOLTAGE Over voltage controller is active Check for and correct e Static or transient overvoltages in the input power supply e Insufficient deceleration time parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2 e Interaction with external input filter 2003 UNDERVOLTAGE Under voltage controller is active Check for and correct e Undervoltage on mains 2004 DIR LOCK The change in direction being attempted is not allowed Either e Do not attempt to change the direction of motor rotation or e Change parameter 1003 DIRECTION to allow direction c
91. rrent 0 20 mA load lt 500 Q 9 AGND Analog output circuit common connected internally to chassis gnd through 1 MQ 10 24V_ Auxiliary voltage output 24 VDC 250 mA reference to GND short circuit protected 11 GND Auxiliary voltage output common connected internally as floating 12 DCOM Digital input common To activate a digital input there must be gt 10 V or lt 10 V between that input and DCOM The 24 V may be provided by the W ACH550 X1 10 or by an external 12 24 V source of either polarity 2 13 DI1 Digital input 1 programmable Default start stop 14 DI2 Digital input 2 programmable Default not configured 15 DIS Digital input 3 programmable Default constant preset speed 16 DI4 Digital input 4 programmable Default safety interlock 17 DI5 Digital input 5 programmable Default not configured 18 DI6 Digital input 6 programmable Default not configured 19 RO1C Relay output 1 programmable Default Ready 20 RO1A Maximum 250 VAC 30 VDC 2 A NI Minimum 500 mW 12 V 10 mA i 21 RO1B _ z 22 RO2C Relay output 2 programmable Default Running gt Maximum 250 VAC 30 VDC 2A 23 RO2A gt _ Minimum 500 mW 12 V 10 mA amp 24 RO2B _ O 25 ROBC Relay output 3 programmable Default Fault 1 26 RO3A Maximum 250 VAC 30 VDC 2 A DOA Minimum 500 mW 12 V 10 mA
92. ry or your local ABB representative Safety ACH550 Installation Operation and Maintenance Manual Contents This manual is the Operation and Maintenance Manual for the ACH550 Drives Complete technical details and programming information are available in the ACH550 User s Manual publication number 3AUA0000081823 1 To determine the type of your drive refer to its construction code on either e Serial number label attached on upper part of SW the chokeplate between the mounting holes stro e Type code label attached on the heat sink on the side of the enclosure LUAU AAT SN 2030700001 3 PH 48 63 Hz 1 PH 4 63 Hz ABB Inc Made in USA of foreign parts Voltage U1 200 240 Vac 200 240 Vac Current I1n 59 4 A 59 4A kAIC Output 3 PH 0 500 Hz 3 PH 0 500 Hz Voltage U2 0 U1 Vac 0 U1 Vac Current 12n 59 4 A 28 Power Pn 20 HP 10 HP CE O Mfg Date 01 December 2005 Org Firmware V 2 06B S N 2030700001 Construction code 2 According to the construction code proceed to your drive s installation operation diagnostics and maintenance information e UH Below e VCR VDR BCR BDR E Clipse Bypass page 39 e PCR PDR Packaged Drives with Disconnect page 77 ACH550 UH Installation Study these installation instructions carefully before proceeding Failure to observe the warnings and instruc
93. s oe olts 400 ACH550 BxR 486A 4 R8 ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 51 Erime Maximum Wire Size Capacities of Power Terminals HP Identification Size Circuit Disconnect Motor Ground Breaker Switch Termination Lugs 500 600 Volt ACH550 BxR 02A7 6 R2 ACH550 BxR 03A9 6 R2 5 ACH550 BxR 06A1 6 R2 8 6 4 7 5 ACH550 BxR 09A0 6 R2 62 in lbs 8 30 in lbs 35 in lbs 10 ACH550 BxR 011A 6 R2 7 in lbs 15 ACH550 BxR 017A 6 R2 20 ACH550 BxR 022A 6 R3 2 25 ACH550 BxR 027A 6 R3 50 in lbs 30 ACH550 BxR 032A 6 R4 4 40 ACH550 BxR 041A 6 R4 1 18 in lbs 2 62 in lbs H 2 50 in lbs 50 ACH550 BxR 052A 6 R4 Eee 120 in lbs 60 ACH550 BxR 062A 6 R4 i 75 in lbs 75 ACH550 BxR 077A 6 R6 1 0 1 100 ACH550 BxR 099A 6 R6 300 MCM 70 in lbs 53 in Ibs 3 x 3 0 125 ACH550 BxR 125A 6 R6 274 in lbs 300 MCM 250 MCM 250 in lbs 150 ACH550 Bx R144A 6 R6 275 in lbs 300 in lbs ACH550 E Clipse Bypass 52 ACH550 Installation Operation and Maintenance Manual Basic control connections for E Clipse HVAC Default E Clipss HVAC Default Terminal for Signal Cable Snieid Analog Input 1 Analog Input Common 10V 10mA Reference Voltage for Potentiometer Analog Input 2 Analog Input Common Speed Reference Process Secpoint Process Feedback Signal
94. table settings for instantaneous current protection The factory default settings are practical for most applications Refer to the ABB SACE Instruction Sheet supplied with these units for additional information on the adjustment of these settings E Clipse bypass configurations The ACH550 with E Clipse Bypass is an ACH550 AC adjustable frequency drive in an integrated UL type 1 UL type 12 or UL type 3R package with a bypass motor starter The ACH550 with E Clipse Bypass provides e Disconnect switch or circuit breaker with door mounted control lever The lever can be padlocked in the OFF position padlock not supplied e Bypass starter e Motor overload protection e Local operator panel with indicating lights and multifunction display e Provisions for external control connections e Embedded communications for major BMS protocols including BACnet Johnson Controls International N2 Siemens Building Technologies FLN and Modbus e Optional fieldbus adapters for connection to additional BMS protocols including LonWorks and Ethernet e Optional drive service switch drive input disconnect the functional equivalent of a three contactor bypass arrangement ACH550 E Clipse Bypass 60 The following shows the front view of the ACH550 E Clipse Bypass vertical ACH550 Installation Operation and Maintenance Manual configuration and identifies the major components The following shows the front view of the ACH550 E Cl
95. the end of the previous series of control panel settings and checks In order to prevent the motor from running without disconnecting the motor open the Run Enable and Safety Interlock contacts on bypass control board terminals X2 2 X2 3 and X2 4 before applying power Set the bypass to Drive mode and the drive to OFF ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 55 3 Apply power to the E Clipse Bypass unit The ACH550 Control Panel display should be illuminated On the bypass control panel both the display and Enabled LED should be illuminated If the Enabled LED is not illuminated solid green check to see that closed contacts or jumpers connect terminal X2 3 to X2 4 and X2 2 to X2 7 on the bypass control board 4 The Drive Selected LED should be illuminated If not press the Drive Select key to switch to Drive mode Leave the system in the Drive mode when proceeding to the next step 5 Press the Hand key on the ACH550 Control Panel Press and hold the UP key until the motor just starts rotating Note If the ACH550 Control Panel displays an OVERCURRENT or EARTH FAULT disconnect and lock out power to the E Clipse Bypass unit Wait at least 5 minutes Disconnect the motor leads from the E Clipse Bypass unit and Megger each motor lead to ground to determine if the motor is good Check the power leads from the Drive Bypass to the motor for damaged or improper wiring If the ACH550 Control P
96. tion exist ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 73 Alarm Alarm Name In A Code Panel Alarm Possible Cause Corrective Action 4011 MTR UNDERLOAD Alarm comes at half the NA Parameter 3002 is the time of a mtr underload time fault See fault 3017 for Parameter 3003 is the further text level 4012 BYPASS Alarm willbe generated NA NA DISABLED if parameter 1613 is set to Disable 4013 DRIVE LINK Same as Fault 3019 Bad cable between Proper seating of cable ERROR however will occur drive and bypass in drive and when not in supervisory Communication RBCU connector J3 mode improperly set in drive Check drive parameter Parameter 98 02 and 99 02 98 02 Modbus Check drive Group 53 Application Macro in Follow DriveLink 99 02 set to 15 text 9 OW tiated recovery procedure 4014 DRIVE TEST Alarm is generated NA NA when bypass parameter 1617 is set to enable 4015 START DRIVE 1ST Message displayed on NA Run drive in Hand initial out of box power up sequence 4016 INP VOLTAGE 3 Phase input voltage NA Loose J7 connector LOW has not reached a Low input voltage sufficient level to Incoming voltage has enable editing of not reached at least parameters via the 155 VAC within a few keypad This message seconds of powerup is generated within a few seconds of power up 4019 OVERRIDE 1 Alarm is generated NA Check Parameter when Smok
97. tions at U1 V1 and W1 are connected and tightened as specified The input power branch circuit protection is installed The motor connections at U2 V2 and W2 are connected and tightened as specified The input power motor and control wiring are routed through separate conduit runs NO power factor compensation capacitors are in the motor cable The control connections are connected and tightened as specified NO tools or foreign objects such as drill shavings are inside the drive NO alternate power source for the motor such as a bypass connection is connected no voltage is applied to the output of the drive 7 Re install cover ACH550 UH ACH550 Installation Operation and Maintenance Manual 19 8 Apply power Always re install the covers before turning power on WARNING The ACH550 will start up automatically at power up if the external run command is on Apply input power When power is applied to the ACH550 the green LED comes on Note Before increasing motor speed check that the motor is running in the desired direction To change rotation direction switch motor leads as shown below Drive QU1 QVI QWI1 CGND QU2 OV2QW2 To change rotation direction switch motor leads Drive QOU1 Ov1 Ow CGND QU2OV2 Qwe NZ L1 Input L2 L3 GND 9 Before Start up The ACH550 has default parameter settings that are sufficient f
98. tions may cause a malfunction or personal hazard AN WARNING Before you begin read Safety on page 2 ACH550 UH ACH550 Installation Operation and Maintenance Manual 1 Prepare for installation Lifting R1 R6 Lift the drive only by the metal chassis Lifting R7 R8 WARNING Handle and ship floor mounted enclosures only in the upright position These units are not designed to be laid on their backs Use a pallet truck to move the transport package enclosure to the installation site 2 Remove the cabinet side panels for access to the cabinet pallet mounting bolts 6 torx screws hold each cabinet side panel in place Leave the side panels off until later 3 Remove the 4 bolts that secure the cabinet to the shipping pallet WARNING Use the lifting lugs bars at the top of the unit to lift R7 R8 drives 4 Use a hoist to lift the drive Do not place drive in final position until mounting site is prepared Unpack the drive 1 Unpack the drive 2 Check for any damage and notify the shipper immediately if damaged components are found 3 Check the contents against the order and the shipping label to verify that all parts have been received Tools required To install the ACH550 you need the following e Screwdrivers as appropriate for the mounting hardware used e Wire stripper e Tape measure e Drill e Frame sizes R5 R8 with UL type 12 enclosure Punch for conduit mounting holes
99. tor from the E Clipse Bypass unit 3 Apply power to the E Clipse Bypass unit by turning on the branch circuit disconnect device and the bypass disconnect switch or circuit breaker 4 The ACH550 Control Panel display should be illuminated On the E Clipse Bypass control panel both the display and Enabled LED should be illuminated If the Enabled LED is not illuminated solid green check to see that closed contacts or jumpers connect terminal X2 3 to X2 4 and X2 2 to X2 7 on the bypass control board ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 57 5 On the E Clipse Bypass control panel either the Drive Selected or Bypass Selected 10 12 13 14 LED should be illuminated Pressing the Drive Select or Bypass Select key should switch the bypass back and forth between the Drive mode and the Bypass mode as indicated by the LEDs above each button Check that the bypass control panel switches the system between modes Leave the system in the Bypass mode when proceeding to the next step Check to see that pressing the e Auto key on the bypass control panel causes the bottom line on the E Clipse Bypass display to indicate Bypass in Auto e Hand key on the bypass control panel generates a Motor Phase Fault e Under normal conditions motor connected pressing the Hand key on the bypass control panel causes the bottom line on the E Clipse Bypass display to indicate Hand A Run e O
100. ttings and checks Apply power to the E Clipse Bypass unit The ACH550 Control Panel should show the operating status of the drive If the E Clipse Bypass Control Panel displays a PHASE SEQ Phase Sequence fault remove power wait at least 5 minutes and then swap any two input phase wires If the motor is a standard 208 V 60 Hz motor connected to a 208 V drive or a 460 V 60 Hz motor connected to a 480 V drive the default parameter settings should be suitable for the initial tests described below If the motor s rating is not 208 V or 460 V 60 Hz the MOTOR NOM VOLT and MOTOR NOM FREQ parameters will need to be properly set before proceeding Refer to the ACH550 UH User s Manual and set the parameters as required Note The settings for ALL external serial communication between the ACH550 with E Clipse Bypass and any Building Automation System are configured using the E Clipse Bypass operator panel DO NOT attempt to configure the external serial communication connection using the ACH550 operator panel The settings for internal communication between the ACH550 and the E Clipse Bypass are configured at the factory and require no adjustment Drive Link recovery procedure If the ACH550 Drive communication settings are unintentionally changed during setup a Drive Link Fault Drive Link Error or Drive Setup alarm may be displayed Should this occur accomplish the following steps in order Using the ACH550 Drive Keyp
101. unit Disconnect motor wires before taking any measurements in the motor or motor wires e Make sure that power factor correction capacitors are not connected between the drive and the motor Enclosure Horsepower Range by Voltage Rating Designation 208 240V 480V 600V V1 V2 1 to 7 5 HP 1 to 15 HP 2 to 15 HP V3 V4 10 to 25 HP 20 to 60 HP 20 to 60 HP B1 1 to 7 5 HP 1 to 15 HP 2 to 15 HP B2 10 to 25 HP 20 to 60 HP 20 to 60 HP B3 30 to 100 HP 75 to 200 HP 75 to 150 HP B4 N A 250 to 550 HP N A ACH550 E Clipse Bypass 40 ACH550 Installation Operation and Maintenance Manual Connection diagrams Vertical E Clipse Bypass ACH550 Vertical E Clipse Bypass units are configured for wiring access from the bottom only The following figure shows the Vertical E Clipse Bypass wiring connection points ACH550 E Clipse Bypass Control Board Terminals X2 Service Switch Optional EW OBO 0 lt El El loo o Output E Terminals Toy Be 4 G g Output Ground _ Lug s iL Disconnect Switch eee fi
102. unit from a Contact ABB at ASM as recorded in the different size bypass 1 800 HELP 365 RBCU unit does not used to replace a Option 4 match drive defective RBCU information Parameters not communicated via 485 matched after link Firmware change 3028 EXT COMM LOSS Time between fieldbus Incorrect Check Group 51 amp 53 messages has Communication Tighten Connections exceeded timeout settings in Group 51 amp Check eat eet itp 29 Barinuinicaien Cable parameter 3005 Poor Connections Grounding Noise on Communication Line 3029 EFB CONFIG Error reading Internal Startup error Cycle Power FILE configuration file for Replace RBCU embedded fieldbus 3030 FORCE TRIP Fault trip forced by Overriding Control Check Overriding external fieldbus System tripped Control System E Clipse unit via fieldbus 3031 EFB 1 EFB 3 Fault code reserved For Bacnet Device Check Parameters 7 for embedded object instances for 5011 5017 and or 3033 fieldbus the drive and or 5311 5317 bypass are set greater than 4194302 in paramters 5011 5017 and or 5311 5317 respectively 3034 MTR PHASE Detects open motor Internal problem Check wiring in phase Detection is Cable problem E Clipse Unit done by current Motor problem Check motor cabling transformers in Check M bypass unit eck Motor Check if 3006 is Disabled 3037 PCB TEMP RBCU unit has Cabinet cooling has Stop drive and let cool reached 190 degrees failed down and restart Bala a Ambient conditions Add add
103. ypass fault is present Drive Faulted LED The Drive Faulted LED is illuminated red when the bypass has lost its communications link with the drive or when the motor or drive protection functions have shut down the drive The specific nature of the fault is indicated on the drive control panel display Refer to the Diagnostics section on page 65 of the ACH550 UH User s Manual for more details Automatic Transfer The Automatic Transfer indication is provided on the bypass control panel The bypass control display will continuously flash an alarm to indicate the system has automatically transferred to Bypass after a Drive fault The Bypass Selected LED flashes green when the system has automatically transferred to bypass operation The bypass event log will also record this event Auto Indication The Auto Indication is provided on the bypass control panel default display when the bypass control panel Auto key is pressed Normally this indicates that the Auto Start contact or serial communications has been selected as the means for starting and stopping the motor in the bypass mode Off Indication The Off Indication is provided on the bypass control panel default display when bypass control panel Off key is pressed Hand Indication The Hand Indication is provided on the bypass control panel default display when the motor has been started manually in the bypass mode Drive Select Key The Drive Select Key selects the drive as the p

ACH550 I, O & M 2011 (Download PDF)

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ACH550 I, O &amp; M 2011 (Download PDF)

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ACH550 I, O & M 2011 (Download PDF)